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Recently I've been looking at the Feldherr case foam line but most of them come standard with foam tray for 25mm bases. Given that standard troops for SM are now 32mm, I am wondering what you guys use and recommend in terms of foam tray sizes that fit well with 32mm base models.

I heard about custom foam with openings for individual models 30mm wide would be recommended. Wide enough to accomodate most infantry models with their heroic poses, and fitting the 32mm bases snugly, so they won't jostle around too much.
Of course, I still have my old Citadel army cases, with the red foam in it. Fits even more snuggly. However, I tend to put in the models alternately right-side-up and up-side-down, to cope with the wider bases inside foam cut for 25mm based models.

While this isn't the answer you are looking for, I find that storing my infantry in foam trays is entirely too time consuming.

Have you considered gluing small magnets to the bottoms of your bases and storing the models in some kind of metal container (I use old biscuit tins)? The models stay perfectly safe and loading/unloading them is so much quicker.