Hot Air Lamination for Multilayer Thermoplastic Foams

Tailor-made solution for the hot air lamination of thermoplastic foams – up to 6 layers

Our multilayer laminating line was originally developed in the early 2000s to meet the growing demand for laminating multiple layers of expanded polyethylene (PE) and polypropylene (PP) foams — widely used in industrial applications.

Over time, the system has evolved to meet new market needs, becoming a modular and fully customizable solution, capable of laminating a wide range of thermoplastic materials with different thicknesses, widths and densities.

A complete, flexible and high-performing laminator

Designed for hot air lamination (air blade system), our technology enables the simultaneous bonding of multiple high-thickness foam layers, ensuring perfect adhesion, dimensional stability and uniform product quality.

Thanks to this process, you can produce both laminated foam planks — strong, resilient and elastic — and other thermoplastic materials that bond using heat alone, with no adhesives or chemical agents.

Whether you work with large foam sheets or complex multilayer combinations, this system guarantees efficiency, flexibility and consistent high-quality output.

🧩 Application sectors for laminated thermoplastic foams

📦 Technical packaging

The shock-absorbing and vibration-damping properties of laminated foams make them the perfect choice for protecting industrial components, electronics, and mechanical parts. The planks can be further converted into custom-shaped packaging solutions.

🏗️ Insulation & Road construction

Multilayer materials with different densities are used as thermal, acoustic and moisture insulation panels in: hangars, cold storage units, modular containers, internal walls, foundations and roofs of industrial and residential buildings.

🏃‍♂️ Sports & outdoor

Laminated foams are widely used in the sports and fitness sectors for their elasticity, lightness and comfort: shock-absorbing inserts for shoes, sports protection gear, outdoor and camping gear, orthopedic and medical supports.

high thickness laminated polyethylene foam EPE

Tailored to your production needs

Each laminating line is designed around your specific process and material requirements.

The lamination heads define the configuration of the machine and determine the number of foam layers (from 2 to 6) that can be laminated in a single step. The line also includes unwinding stations and an integrated foam cutter at the end of the process.

Most requested configurations:

1 Double head → up to 3 layers
1 Double + 1 Single head → up to 4 layers
2 Double heads → up to 5 layers
2 Double + 1 Single head → up to 6 layers

We work closely with each customer to deliver a tailored solution that aligns perfectly with their production goals and material characteristics.

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