Discover Our Tailor-Made Technologies for Your ProductionFrom October 8 to 15, we’ll be in Düsseldorf at K2025, the world’s leading plastics and rubber trade fair.
You’ll find us at Hall 16 / Booth 16D68 – and we’d love to meet you.
When only one machine is not enough: FAP, the value of co-design and collaboration
Industry is evolving, markets are moving fast, and challenges are becoming increasingly complex. In this context, a "one-size-fits-all" technology is no longer sufficient. At FAP, we always start with one thing: the customer's project.
For over 38 years, we have been designing and building tailor-made machines for the extrusion, winding, lamination, cutting, welding and other converting solutions. Now led by the second generation, FAP continues a journey started in 1987, establishing itself as a reliable partner for both Italian and international customers. From large industrial groups to specialized manufacturers, our clients share one common need: they are not just looking for a machine. They are looking for a solution - and for someone who truly listens.
Beyond machines: building success stories together
At FAP, solutions start from a real need - or rather, from a challenge. In recent years, over 70% of our projects have been completely customized. Customers come to us with unique requests, unconventional materials, and often out-of-standard production goals. Whether it’s a twin-screw extruder for foam materials, a lamination line for a patented thermoplastic material, a high-precision cutter for different plastic flexible materials, or a winder designed for high-density or ultra-light rolls, each machine is developed as part of a true collaboration.
✳ Facing the challenge: when standard is not enough
One of the biggest issues in the market today is the lack of flexibility. Many manufacturers only offer what is already in their catalogue. Customization is often limited and expensive. FAP chooses a different path. We walk alongside the customer from day one. Together, we define the problem, explore options, and co-design the solution. This shared approach leads to smarter decisions and machines that not only tackle challenges but open new business opportunities. Our team of mechanical, electrical and software engineers work with great attention to every detail to ensure that the final machine truly reflects the customer’s production and business goals. This is what makes every FAP machine unique.
Real examples of co-design
• A complete extrusion line with a double winding unit, developed together with the customer to produce ultra-thin expanded polypropylene with CO₂, combining energy efficiency with extreme film control precision.
• A lamination line designed to bond high-density thermoplastic material with nonwoven fabric, for a highly technical application in the construction sector.
• A tailor-made cutting machine "not available on the market," capable of precise work on barrier film and other flexible films, where the client needed a completely out-of-standard solution.
"What started as an ambitious idea has become a fully customized lamination line – the very first for our start-up. Together with FAP, we reworked the project multiple times, refining every detail until we reached the right solution. The result? A brand-new production process, built from scratch. What we appreciated most was their ability to stay by our side at every step, combining flexibility with true technical know-how."
✳ The strength of synergy: technologies that adapt to your goals
The FAP offering includes versatile and modular solutions for:
• Extrusion lines for foam film, tubes and profiles, with counter-rotating twin-screw technology for materials like EPE, EPP, EPS, combined with polyolefins such as LDPE + MLLDPE, PP + TPE, PS + HIPS, PP + EVA. One extruder, infinite product diversification possibilities.
• High-efficiency extrusion heads, designed for the production of physically expanded closed-cell polymer foams. They provide consistent structure, excellent cell uniformity and superior quality. Compatibility with gases such as Isobutane, n-Butane, Propane/Butane and CO₂ allows for more efficient, sustainable, and economical production.
• Automatic and semi-automatic winders, designed for ultra-low-density or high densities foams, and bubble films, with various levels of automation.
• Lamination lines, now more in demand than ever, suitable for a variety of sectors for the production of barrier films, multilayer foam materials and special applications. Dedicated for lamination of foam, EVA, bubble film with materials such as HDPE, LDPE, metallized films, paper + HDPE, aluminium + LDPE, metallized lavsan, waterproof polymeric films, nonwoven fabric and others.
• Cutting machines for different flexible plastic materials and thicknesses.
• Bag-making machines for foam and bubble film, flexible, high-productivity and built to last.
✳ Innovating through collaborations
Behind every technology there are people, visions and shared choices. Our approach to innovation comes from this awareness: working together, in open dialogue with those who share the same goals. We shared this story during the international webinar "Advancing Foam Sustainability", organized with Borealis, one of the world’s leading suppliers of sustainable polyolefin solutions. On that occasion, we showcased how our latest CO₂ foam technology, combined with HMS PP Daploy™ from Borealis and Royce Global functional additives, is revolutionizing foam production, improving both sustainability and industrial efficiency.
A few months later, we were invited to the Borealis Innovation Headquarters in Linz for two days of technical exchange and co-design. It was a concrete opportunity to further develop counter-rotating twin-screw extruders, a technology that FAP continues to evolve in close synergy with its customers, to meet increasingly complex production challenges. These technical networking moments are more than just visibility opportunities: they are real growth milestones for us, where knowledge is exchanged, ideas are challenged and solutions take shape from different perspectives - but united by one goal: building the future of industry.
✳ Sustainable foam: trials with PCR LDPE
New European rules are reshaping the packaging industry: by 2030, all packaging must be recyclable, contain post-consumer recycled (PCR) material, and move towards reuse and refill. For producers, this is not just compliance – it’s a transformation.
So we recently joined forces with Ravago, Sabic and Borealis to test PCR LDPE granules on a small-scale FAP twin-screw foam extruder, exploring formulations with high recycled content. The results? High quality foam, reliable performance, even at low densities. For us, these trials are not only a way to support our customers, but also a message to all foam packaging producers: by staying closely connected with raw material suppliers, we make our technology available to process even the most demanding new materials shaped by environmental requirements. Because anticipating change together is the best way to turn compliance into competitiveness.
But this year, there’s more than just technical solutions.
✳ A Space for Values. A Space for People.
Inside our booth, we’re creating something unexpected and emotional.
It’s not about automation or technical features. It’s about what makes us human.
At FAP, we believe that our values are the real roots of everything we do. Each month of this year, we highlight one core value - Listening, Integrity, Efficiency, Innovation - and show how it drives our daily work, from engineering to after-sales service.
At K2025, we’ll celebrate these principles with a dedicated Values Corner – a space to pause, reflect, and reconnect with what matters most.
Because in today’s world, where automation, high-speed production, and streamlined processes dominate, we need to remember what keeps companies and people grounded.
Like the roots of a tree, values are invisible but essential: they support growth, give direction, and connect us to something meaningful - even as everything around us accelerates.
✳ Stop by Our Booth...
With more than 3,000 exhibitors at K2025, it’s easy to get lost in the noise of machines and innovation.
That’s why we invite you to slow down and meet us.
Not just to explore high-performance foam extrusion technology for example, but to have a real, valuable conversation.
Let’s talk about your production challenges, your goals, and how we can support you create your next big success - with technology that fits your process, and a team that’s here for you.
Because your project deserves more than a standard solution.
It deserves our expertise - and our attention.
📍 We’re already scheduling meetings for K2025.
If you’d like to reserve a time slot, get in touch with us.
We’ll be there.
Will you?
