FAP designs and manufactures the most flexible and high-performance foam extrusion lines on the market. Entirely Made in Italy, our machines are built to deliver consistent quality, outstanding productivity, and full process control — from raw materials to finished rolls.
With a single FAP foam extrusion line, you can produce a wide range of expanded closed-cell foam materials, tailored for multiple applications and industries.
Our twin-screw extrusion technology allows for the production of:
Expanded polyethylene (EPE) foam: from 0.5 to 30 mm
Expanded polypropylene (EPP) foam: from 1 to 10 mm
Foam densities ranging from 15 to 400 kg/m³
Output max. capacity of FAP extrusion lines: from 100 to 1200 kg/h
This means maximum flexibility, whether you work with thin, thick, light, or high-density foams.
The Key competitive advantage of FAP foam twin screw extrusion lines with counter-rotating technology.
✅ High-precision dosing with an accuracy of ±0.3%
✅ Independent dispensers with dedicated screw and motor
✅ Quick recipe changes (e.g., nucleator or dye) in under 7 minutes
✅ Automated raw material feeding and real-time recipe deviation alerts
✅ Uniform melting and mixing
Screw rotation grinds the polymer at the contact point, reducing local overheating and ensuring consistent melt quality.
✅ Microcell foam technology
Our unique mixing zone enables perfect gas dispersion, unlocking the production of fine-cell (microcell) polyethylene foam.
✅ Wave-free surface at low pressure
Foam stays flat and smooth even with low die outlet pressure, ideal for laminating and thermoforming applications.
✅ Low-temperature homogenization
No need for high melt temperatures — reduce thermal stress and improve material stability.
✅ Energy-efficient design
Optimized extruder design ensures low energy consumption without sacrificing performance.
Efficient recipe switching with minimal time
Change dyes or recipes in under 5–7 minutes, minimizing waste and boosting production uptime
Reduced material loss and downtime
FAP’s custom-designed extrusion dies (extrusion heads)for thin/normal thicknesses and for thick thicknesses guarantee perfect control of material flow and thickness, from thin foam films to thick ones.
After extrusion, the tubular foam is slit, expanded and cooled on dedicated supports before winding — preserving the integrity of the foam structure while it’s still “alive.”
Our Soft Wind System was developed specifically for EPE/EPP foams. It ensures:
Controlled tension between roll layers
Uniform thickness across the entire roll
Correct post-degassing development of the foam
100% automated cutting system
Optional units: automatic core gluing, longitudinal cutting, and reel unloading
The automation of FAP foam extrusion lines can be configured in modules to include:
Real-time process visualization
Smart alerts and remote supervision
Integration with automatic winding and handling systems
Seamless recipe management and traceability
FAP Srl is a member of AMAPLAST Italian Plastics and Rubber processing machinery and
moulds manufacturers’ association.
