Extrusion Lines for PE & PP Foam / Foam Machines

FAP’s foam machine is a twin-screw counter-rotating complete Extrusion Line for Polyethylene (PE) & Polypropylene (PP) Foam, robust and reliable, designed to work continuously, guaranteeing constant quality. The PE foam & PP foam machines are made adopting the most advanced technologies including the new high energy efficiency system; the processes are stable and easy to be run by the operators for 24-hour day 7/7, minimizing industrial waste.

Thanks to experience and high professionalism, FAP team offers complete "turnkey" project and services that include the design phase, assemblage and installation, start-up of machinery, staff training with know-how transfer.

• The twin screw counter rotation technology ensures uniform melting and mechanical mixing of the polymer by grinding the material at the point of contact of the screws. “Turning over” the melt significantly reduces the local overheating temperatures of the melt.
• The special shape of screws allows obtaining the homogeneous mixing of the melt and the better control during the mixing process.
• The unique mixing zone allows the gas to be evenly dispersed into the melt, which opens up the possibility of producing polyethylene (EPE) foam with "microcell" technology.
• Ability to produce wave-free material at low die outlet pressure.
• The time of mixing the dye with the polymer in the extruder takes only 7 minutes, and accordingly, the time to change any material or adjust the technological process takes no more than 7 minutes.
• There is no need to use high melting temperatures for homogenization.
• This extruder technology is extremely energy efficient.

Learn more about advantages of our twin-screw foam extruder

Extrusion is the most commonly used foaming technology. It can be used to produce polyethylene (PE) and polypropylene (PP) foams of various densities. In the physical foaming process, hydrocarbons (such as isobutane or n-butane) are used to produce ultra-low and low-density foams. Inert gases, like supercritical nitrogen (N2) or carbon dioxide (CO2) are typically used to produce higher density foams of 100 - 150 kg/m3 or more.

The direct injection extrusion process transforms plastic PE or PP pellets into expanded film (non cross link with closed cell structure polyethylene or polypropylene foam, can be 100% recycled). 

The exclusive and original designing of extrusion heads has been studied by FAP for excellent control of the material and its distribution inside before the exit.

• How can we effectively organize the production of PE and PP foam?
• What are the key requirements for the project?
• How can we standardize the technological process and train our production staff?
• How can we develop and success fully mass-produce a new product of PE foam and/or PP foam?
• How can we address technical issues in production related to waste formation and defects in the production process?
• Which raw materials and technological additives should be utilized for manufacturing foam material products?
• How can we reduce the impact of over production and increase productivity?
• What is the best and most efficient way to schedule equipment maintenance in order to prolong its service life?
• What is the optimal and most ergonomic approach to organize warehouse logistics for foamed polymers?