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This paper addresses on study of development of new packaging material comprising Expanded Polystyrene Spheres (EPS) embedded epoxy polymer based sandwich composites with aluminium skin. The density of the packing material is controlled by varying the volume of embedded spheres. In this study, the Flexural and Compression performance of Expanded Polystyrene Spheres (EPS) embedded polymer based sandwich composites with aluminium skin are investigated. The EPS volume percent in the core is 25% with epoxy matrix which makes the the density less than 1 g/cm3 for the composite. The fabricated Sandwich Composite are very light weight, the density is less than 1 g/cm3 so it can able to float in water. Here for the same volume fraction of 25%. EPS are arranged in square pattern and hexagonal pattern in the sandwich composites. The compression strength and flexural strength for the two type of pattern arrangements were studied in experimental method.