Extrusion Lines for PE & PP Foam / Foam Machines

FAP’s foam machinery are twin-screw counter-rotating complete Foam Extrusion Lines for polyethylene (EPE) foam, polypropylene (EPP) foam and polystyrene (EPS) foam. They are robust, reliable and designed for continuous operation, ensuring consistent quality at all times.
Each foam extrsuion line is built using the most advanced technologies, including a new high-energy-efficiency system.
Processes remain stable and easy for operators to manage 24/7, 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), polypropylene (PP) foams and polystyrene (PS) foam 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, PP or PS pellets into expanded film (non cross link with closed cell structure polyethylene, polypropylene or polystyrene 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.

FAP continues to invest in the development of sustainable solutions for the extrusion of foam materials,
with a concrete focus on process efficiency and environmental impact.

FAP foam extrusion lines are designed to process a wide range of polymers and recycled blends, including formulations with a high percentage of Post-Consumer Recycled (PCR) content. During recent test activities, we confirmed the ability of FAP extrsuion technologies to successfully process materials with over 70% certified PCR, achieving lightweight and stable foams with mechanical properties aligned with our customers’ production requirements.

What this means for our customers

• The possibility to integrate high-PCR materials without compromising quality, stability, or productivity.
• Improved performance when processing sensitive blends, thanks to precise control of temperature, homogenization, and gas distribution.
• More sustainable manufacturing processes, reducing overall environmental impact.
• Compliance with upcoming environmental regulations and growing market demand for low-impact products.

We collaborate with international partners to implement physical foaming technologies that use eco-friendly blowing agents such as CO₂, further improving the sustainability of the extrusion process.

Italian technology for a more responsible future

Our mission is to enable manufacturers to produce high-quality foam using more sustainable materials and processes, while maintaining high production efficiency and opening new application opportunities.