Top EPE & EPP Foam Extrusion Lines | FAP Made in Italy

Italian Engineering, Global Performance

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.

High thickness ultra low density polyethylene PE foam produced on FAP extruder

Foam twin screw counter rotating extruder for different densities and thickness

One Line, Multiple Applications

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.

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twin screw counter rotating foam Extrusion line

Internal workshop for production of parts

high foam thickness production on FAP extrsuion line

Why FAP? Unmatched Competitive Advantages

Smart Dosing System

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

Twin-Screw Counter-Rotating Technology

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.

advantages of twin screw counter rotating foam extruder

Fast Setup, Minimal Waste

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

Optimized Extrusion Round Dies (Heads) and Accurate Cooling Process

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.”

Automated Winding with Soft Wind Technology

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

FAP winders are universal and can be integrated into any existing foam production line.

Modular Automation for Real-Time Control

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

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