Why is it so important to choose the correct GMS dosing during the foaming/expansion process to produce high quality PE (polyethylene) or PP (polypropylene) foam material?
Simply because GMS, being an emulsifier and one of the most significant components, has a huge influence on many factors.
Let’s examine the following three main factors that help you to avoid the common mistakes:
Surface tension during foaming - in simple terms, this is the effect that occurs as a result of the expansion of the blowing agent (butane, CO2 and others) when heated in the extruder, precisely when the blowing agent stops flowing and forms a new cell during critical expansion, and stretches the walls of already formed cell. GMS reduces the surface tension during expansion, helps and improves the process of cell’s formation (gas structural element).
An increase in the GMS input on the one hand improves the foaming process, but at the same time a large concentration of GMS migrates from the lower layers of the foam to upper layers and creates an obstacle for the replacement of gas with air, which leads to an increase in the conditioning time of the rolls in the warehouse and the rupture of the foam structure (formation of cell), since the gas in the foam structure expands after production. Also, a high gas residue in the foam structure and a high concentration of GMS on the foam surface can have a negative effect on the quality of lamination in the future.
At the same time, an insufficient concentration of GMS contributes to a sharp release of gas before the foam matures and, as a result, collapse of the foam occurs. Therefore, it is very important to control the dosing of GMS through experience and by carrying up tests during production, avoiding excessive or insufficient concentration.
Reduction of static charges on the surface of the foam during the production process - static charges accumulate on the surface of the foam as a result of friction - thus reducing the risk of fire
The lower the density of the foam (kg/m3) and the saturation/gassing of it, the more the GMS will influence these factors.
The problem of many foam producers/manufacturers working with ultra-light, low density foams is mainly the shrinkage or rapid expansion of the foam during the conditioning process in the warehouse and the resulting formation of "bubbles" and breaks on the surface. The use of various additives "Anticolaps" in addition to GMS does not make a lot sense, because Anticolaps works exactly in the same way as GMS.
The correct dosing of GMS depends on many factors such as foam density, raw material dosage kg/h, ambient temperature, ambient humidity, temperature fluctuation during the day and night, and so on. Therefore, it is very important to choose the correct dosage/concentration of GMS during the foaming process.
Thanks to everyone who came visit us, clients, partners & suppliers, foam and future foam producers, foam & bubble film transformers who wanted to know more about our foam technology & converting solutions and modernize the productions with the most innovative and versatile solutions in foam industry!
8 days of new ideas and fantastic visits, collaborations and news!
For our FAP team this show was the 8th one since 2001 and it was really fantastic to exhibit again in such great event!
FAP continues to develop and grow, constantly looking for new solutions for foam production and converting lines, which have already reached an impressive level of productivity and quality in the production of polyethylene and polypropylene foams in recent years! Stay tuned!
See you again at the next edition K2025!
Visit us at K 2022 - The World's No.1 Trade Fair for Plastics and Rubber.
When: 19 - 26 October 2022, Dusseldorf, Germany
Where: Hall 16 / D68
And for our FAP team this show will be the 8th one since 2001, and we are sure it will bring a lot of new and interesting opportunities and collaborations.
Over the past decades, the global market has experienced many difficulties, but every decline is followed by new growth, new ideas, solutions. The personal contact has been and remains an indispensable tool for building strong relationships between the manufacturer and the producer.
For FAP K exhibition has been always an important tool for business global development, which allowing to create favorable conditions for the interaction of business partners, demonstrate relevant solutions and introduce innovations in the polymer industry.
FAP continues to develop and grow, constantly looking for new solutions for foam production and converting lines, which have already reached an impressive level of productivity and quality in the production of polyethylene and polypropylene foams in recent years!
FAP's lines are synonymous of no-stop productivity, reliability, low waste production and unparalleled quality of polyethylene and polypropylene foam. And FAP's team offers the complete support in each stage of project creating the long-term collaboration with clients.
Thats why we invite all our clients to contact us to get an entrance voucher.
WE CELEBRATE OUR 35 YEARS OF ACTIVITY. WE COMBINE 𝗣𝗔𝗦𝗦𝗜𝗢𝗡 FOR A JOB WELL DONE WITH THE 𝗕𝗘𝗦𝗧 𝗧𝗘𝗖𝗛𝗡𝗢𝗟𝗢𝗚𝗜𝗘𝗦.
FAP team wishes all participants fruitful and efficient work!
FAP is dedicated daily to the development of new solutions and innovative applications not yet present on the market, always trying to anticipate the needs of foam producers and the market. To meet the customers’ needs, and to ensure precise and complete answers, FAP has created an internal lab to test granules and to produce foam materials in little scale. During the last years numerous tests were carried out together with customers, producers of raw materials and research centers.
Thanks to the numerous requests in the recent months the samples of high-density polypropylene (PP) and polyethylene (PE) foam have been produced and tested, perfect for being thermoformed and laminated with the final use in various industrial sectors such as automotive, construction and food.
Furthermore, today the company is the protagonist of a courageous entrepreneurial choice. FAP invests over 5 million euros to build the site which provides the expansion of the new production area, that nowadays has become insufficient to manage the ever-increasing number of orders. Also, the laboratory will be brought in Italy, creating an innovative research and development internal center for study and tests of expanded plastic materials in industrial scale, that has already solicited requests by companies all over the world including for example Brazil, Chile, Saudi Arabia, United States, France, Spain, Russia. The construction site will be completed in 2023.
"We collaborate with companies that work, produce and study polymers: today companies have the opportunity to carry out tests in the French laboratory, but not to continue experimenting on industrial production machines”, Fabrizio Poli explains. “We build these machines and we want to share our rich experience creating a line specially dedicated for tests in industrial scale. Moreover, this center will be used by our company for the study of new materials and to improve processes in terms of energy efficiency", continues Poli, who has already established relations with the Polytechnic of Milan for the evaluation of an innovative material that FAP is patenting. "We are talking about a replacement of polystyrene material for the food sector with 100% recyclable foam produced using 100% natural gas CO2", Poli concludes.
The news concerning FAP reconfirm the ambition and determination of the Italian company in current economic context strongly impacted by Covid-19 situation.
|Despite all the difficulties of this period and thanks to the work of FAP team, we managed to achieve not only successful indicators in R&D field, but also to attract some new customers. After the vacation, we will be back full of energy and will continue to work this year even more successfully than ever before. |
Thanks to all our clients, partners and suppliers for the support and collaboration during this period.
We will reply to all emails when we return.
Welcome to FAP! Welcome to our family!
Over 35 years of history, FAP has sold complete lines to leading producers of non cross-linked polyethylene (PE) and polypropylene (PP) foam, always guaranteeing the service and reliability of its technology.
The key to FAP’s success is based on pillars such as: hard work, concreteness, reliability and quality 100% made in Italy.
FAP distinguishes itselves from competitors because the plants only have proprietary technology, which is the result of constant dialogue with the production departments of customers.
Each plant meets the requirements of Industry 4.0 to ensure the customer maximum efficiency, reduced energy consumption, accurate control of temperatures, pressures, raw materials and gas consumption.
FAP is focusing on long-term partnership and continuous improvement to help customers to achieve their goals.
Contact us: email@example.com
Follow us: https://www.linkedin.com/company/fapitaly/
Visit us at PLASTIMAGEN® MÉXICO 2022 - one of the most important plastic industry exhibitions for Mexico and Latin America entire regions. We will be located in Hall A, Stand 3030.
When: 8-11 March 2022
Where: Centro Citibanamex, Mexico City
The official representative of our company will be Danemach Latín América S.A. that since 2003 provides professional services and representative of machinery manufacturers specialized in the plastic processing and conversion industry in different applications.
The personal contact has been and remains an indispensable tool for building strong relationships between the manufacturer and the client. So from this great event we will waiting to create new collaboratirons from following sectors such as: packaging, construction, automotive, electronics, food and others.
FAP continues to develop and grow, constantly looking for new solutions for its extrusion lines, winding machines, laminating units and cutting and welders machines, which have already reached an impressive level of productivity and quality in the production and transformation of polyethylene and polypropylene foams in recent years!
With the hope that Plastimagen Mexico will bring a lot of new and interesting opportunities, FAP team wishes all participants fruitful and efficient work.
Visit us at Interplastica 2022 - one of the plastic industry leading exhibitions in Russia and Eastern Europe.
When: 𝟮𝟱 - 𝟮𝟴 𝗝𝗮𝗻 𝟮𝟬𝟮𝟮, 𝗠𝗼𝘀𝗰𝗼𝘄, 𝗥𝘂𝘀𝘀𝗶𝗮
Where: 𝗕𝗼𝗼𝘁𝗵 𝗖𝟮𝟱, 𝗣𝗮𝘃𝗶𝗹𝗶𝗼𝗻 𝟮
The official representative of our company will be company Avexx, a representative of the leading European manufacturers of equipment for polymer processing.
Over the past decades, the global market, and especially the Russian market, has experienced many difficulties, but every decline is followed by new growth, new ideas, solutions and opportunities.
The personal contact has been and remains an indispensable tool for building strong relationships between the manufacturer and the client.
The Interplastica exhibition has been always an important tool for business development, which allowing to create favorable conditions for the interaction of business partners, demonstrate relevant solutions and introduce innovations in the polymer industry.
FAP continues to develop and grow, constantly looking for new solutions for its production lines, which have already reached an impressive level of productivity and quality in the production of polyethylene and polypropylene foams in recent years!
With the hope that Intepalastica will bring a lot of new and interesting opportunities and collaborations, FAP team wishes all participants fruitful and efficient work.
With sorrow we inform you that that our dear colleague and friend Alexandre Dyminski passed away.
In many years of intense activity he has given support and great development to FAP. He has always passed on his passion for work to us and he has given us his sincere friendship.
We will miss his support and his constant, constructive and positive presence, his imprint remains indelible in the many personal relationships developed with customers.
A WIDE-RANGING INTERVIEW WITH FABRIZIO POLI, CEO of FAP, WHO RUNS THIS FAMILY FIRM TOGETHER WITH HIS BROTHER FRANCESCO, THE SALES DIRECTOR.
The best advertisement for FAP has always been innovative, high-quality machines, on which clients can build the success of their enterprises.
These are words of Luigi Poli, who in 1987 founded FAP, a company based in Besana in Brianza (Monza Brianza) that builds extrusion plants and specializes, in particular, in systems for producing foam film. His words perfectly encapsulate the philosophy that, stemming from the typical Brianza mindset (a trait recognized both in Italy and internationally), has always guided this company. Indeed, Brianza people are committed to their work, even when the going gets tough, and they regard their products as the best possible testimony both to themselves and to their businesses.
In 2020, the reins of the company passed to Fabrizio and Francesco Poli. The two brothers both joined the family firm when they were very young. Accordingly, after lengthy “apprenticeships” in the various departments and in various roles, they are now entrepreneurs with considerable experience to bring to bear, despite their still relatively young age. Today, they are engaged not only in the day-to-day running of the company, but also in a drive to raise the level of every aspect of its operations through major investments of the kind that, especially right now, demand a good deal of courage and expertise. Clearly, two brothers have both these qualities in spades. To get all this straight from the horse’s mouth, we interviewed Fabrizio Poli. Our thanks go to him for giving us his time. This is what he had to say.
Let us start by talking about your specialisation, namely the construction of lines for the extrusion of foam materials. Could you outline the state-of-the-art in this field and your own most recent technological developments?
“FAP has over thirty years’ experience in the foam film sector. Through our research and development laboratory in France, we study new applications made possible by materials that have yet to reach the market, so that our technology can be made suitable for processing them. In other words, we always try to anticipate the needs of processors and the market, to be sure we are ready”.
Has Industry 4.0 changed the plants you build and your company’s internal processes? If so, how?
“For years now, the manufacturing sector has been going through an unprecedented process of transformation thanks to technologies such as robotics, artificial intelligence and augmented reality. At FAP, we have invested heavily in Industry 4.0, improving both access to data and the management of the extrusion process, so as to allow our customers to become more competitive, especially in terms of efficiency, precision and reduction of production costs”.
How is your reference market faring in these difficult times?
“We experienced a slowdown in March 2020 but bounced back almost immediately. Even though all sectors have been impacted by the Covid-19 crisis, fortunately our customer base is made up of companies that operate across a range of different ones, and have therefore felt the effects of this difficult situation less than they might otherwise have done. Thanks to their very high technical performance levels, foam films are used widely in numerous industrial fields, such as packaging, construction and the automotive industry. What is more, as an effect of imminent restrictions on the marketing and use of food containers made of polystyrene foam, we are seeing an increase in the demand for 100% recyclable solutions from food companies that are going to have to replace their products in polystyrene foam. We are therefore carrying out numerous tests in our laboratory in order to be able to offer our customers the best solutions to do just this. Our estimates suggest that 2021 will see our turnover further increasing on previous years”.
Speaking of Covid-19, what repercussions has the pandemic had on you, and how did you organise your work in the face of the emergency? Did you have to close or reorganise your production in any way?
“We closed the company in April 2020. At that time, of course, there was widespread fear, a lack of PPE, and no clear indications on the issue of workplace organisation. For us, like all companies, prioritising the health of our employees and collaborators has meant reorganising things, in other words, redistributing work spaces, sanitising common areas, making sure everyone has access to PPE and sanitising gels, and setting up training courses on safety protocols to follow within the company”.
Could you tell us about your investments in the renovation and expansion of your factory? What stage are you at, and what interventions are planned?
“Work on our new production site, which will also be in Besana in Brianza (Monza Brianza), is scheduled to begin in July. The project involves expanding the production area, which is now insufficient to manage our ever-increasing number of orders. Furthermore, we will be moving our research and development laboratory to Italy, thereby expanding our international research centre here”.
You have recently undergone an image and communications makeover. Could you tell us more?
“We are a serious company, committed to our customers, and this, together with our achievements, says a lot about us. However, we wanted to make sure our story also reaches those who still don’t know us. It has always been widely accepted that a company’s logo is an essential element in defining its image. We have therefore had ours restyled and also given our website a makeover, to make it simpler and more modern. We are very pleased with the result and feel that our new logo really reflects what we are today: a dynamic family business with a long history of success, as well as solid and constantly growing international experience”.
These new investments suggest that you are really striving to forge ahead with your business. Will this drive include the recruitment of new technical and sales staff?
“We have already embarked on a quest to find new people to add to our R&D and technical teams. We have started this process early because we attach great importance to the recruitment side of things. After all, the daily efforts of our staff are the foundation of the company’s success”.
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