Because increasing the speed of customer order fulfillment means increased productivity and margins.
It takes knowledge and a lot of field experience. In our 37 years of work in the field of polyethylene and expanded polypropylene, we have learned to recognize, predict and eliminate every possible bottleneck in the production process.
In the production of expanded polyethylene and polypropylene, the main limitation is usually faced during "Degassing": the phase in which gas is replaced by air. This process has a significant impact on further processes, e.g. at the lamination stage: it is impossible to start the process if degassing has not been completed, and it also has a significant impact on product storage costs.
- Acceleration of delivery times: reduction of process waste in production = reduction of production batches to minimum cost-effective size.
- Optimising logistics: reducing the number of finished and semi-finished products in stock = increasing the turnover rate.
- Optimising production costs with FAP technology.
The technological and technical features of FAP extrusion lines are designed to increase the performance of the company's whole production system, including storage costs, raw material costs, and workforce productivity.
On this special day, we also extend our heartfelt wishes to the amazing community of Women In Plastics (WiP). Together, we are breaking stereotypes, fostering diversity, and creating a more sustainable and inclusive world for generations to come 💚
Women in Plastics is a group of women active in the world of plastics, determined to unite and combine their forces to create a point of reference that gives voice to the female universe of the industry.
The amount of “saved” profit of the company directly depends on an effectively built quality control system and technological processes in the production of foamed polyethylene and polypropylene. The quality service department and qualified process engineers in a company engaged in the production of products from foamed polymers are in no way inferior in importance to other departments, such as the production department or the sales department.
The quality service is a controller independent of production indicators, ensuring the predictability of the work of the production unit and compliance with established indicators. Yes, the productivity and efficiency of a production unit is considered by the volume of quality products shipped that meet all stated requirements, and not by the speed and volume of products arriving from production to the warehouse.
Have you ever wondered how much 1 m2 of defective products costs a company?
For example, the cost of producing 1 m2 of scrap polyethylene foam (PE foam) 5 mm thick (20 kg/m3), processed into secondary raw materials, will cost the company approximately 0.2 euro/m2, and the cost of producing scrap 10 mm thick is approximately 0.43 euro/m2.
Based on this, the cost of 1 kg of defective polyethylene foam (PE foam) products processed into secondary raw materials will cost the company approximately 2.23 euro, which is on average 55% more expensive than the cost of 1 kg of the mixture primary (raw materials and technological additives) in the standard production recipe, foamed polyethylene 5-10 mm thick with a density of 20 kg/m3.
In addition, manufacturing defects have a significant impact on the productivity of the production unit as a whole, as unplanned “overproduction” becomes necessary.
The production of foamed polymers is no exception to the rule, and there are also mandatory criteria for monitoring technological processes, both during the production process and during storage of products, which minimizes the risk of receiving defective finished products. Unfortunately, many companies put this aside because they mistakenly believe that it does not impact the overall performance of the company that critically.
Our Italian Foam Center will help you answer these questions and organize all technological and production processes for the production of foamed polyethylene and polypropylene.
Undoubtedly, the technology of physically foamed non-cross-linked polyethylene and polypropylene is an ideal polymer production technology from a closed-loop point of view, but it is still much more profitable to work with minimal risks of receiving defective products.
We are excited to announce the beginning of a collaboration between FAP and Extrusion Consulting 🤝
This partnership marks a significant moment in our global expansion strategy and is a key step toward strengthening our presence in the U.S. market. Combining the technical skills and experience of both companies will enable us to offer even more innovative and customized solutions to our customers.
This collaboration will not only strengthen our leading position in the foam industry, but also enable us to provide an even more comprehensive service geared to the needs of the U.S. market.
A special thanks goes to the owner of Extrusion Consulting, Dr Bryan Hauger, Ph.D and his team, ready to demonstrate all the great advantages of Italian technology for the production and conversion of foam and air bubbles.
OUR TEAM IS ABLE TO:
- identify and solve bottlenecks in production, increasing speed and productivity;
- optimize process parameters to reduce waste and improve product quality;
- implement best practices and advanced technologies to maximize efficiency;
- reduce raw material and energy consumption through an optimized process;
- reduce maintenance and downtime costs;
- improve product quality control, resulting in reduced rework and scrap costs;
- optimize foam properties according to customer specifications;
- support new product development and optimization of existing products;
- provide access to industry-specific knowledge and expertise;
- take advantage of the latest technologies and innovations;
- develop internal skills and staff training;
- promote awareness of production processes and their interdependencies.
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.
He was always passionate about his Foam Machines, cared for and controlled down to the last detail. He was always present with customers during the Start-up of his foam lines because he considered them as his own children whom he accompanied on the greatest adventures to conquer the world's markets.
Today, the legacy lives on through Luigi's sons, Francesco Poli and Fabrizio Poli, who are actively steering the company towards international success. The FAP team, comprising skilled professionals, plays a pivotal role in elevating the company to new heights.
The passion and dedication inherited from Luigi are evident in every project undertaken by sons, and the entire FAP team. As they continue to build on their father's vision, FAP is not merely a company; it's a testament to the enduring spirit of innovation, creaftsmanship, and familialbonds.
Luigi's memory lives on, not just in the machines that bear his imprint, but in the thriving international presence that FAP is becoming, thanks to the collaborative efforts of the next generation and entire team.
January 12, 2024
It is no secret that each technology has its own advantages and disadvantages. When deciding to invest in the production of polyethylene (EPE) and polypropylene (EPP) foam, it is important to understand:
What materials do you want to produce on foam extrusion line?
The "predictability" and stability of the production process plays a very important role. It must be assured that the quality parameters of the product (geometric dimensions, product density, cell structure, maturation process of the product in the warehouse) will be unchanged in every production batch produced. The foam production line should be automated to reduce the influence of the so-called "human" factor on the technological process of polyethylene and polypropylene foaming, and to make the production process itself safe and highly efficient.
In this article we will give some examples of the competitive advantage of FAP foam extrusion lines with counter-rotating technology for the purpose of comparison with single-screw extrusion technology. We focus exclusively on polyethylene and polypropylene foaming processes by direct injection of pressurized gas into the polymer melt (physical foaming).
In contrast to single-screw extruder technology, twin-screw FAP extrusion technology ensures uniform melt and mechanical mixing of the polymer by grinding of material at the screw contact point, rather than by creating melt backpressure as is the case with single-screw extruder. This positively affects technological factors such as:
One of the main processes in the production of non-crosslinked physically foamed polyethylene and polypropylene is the mixing of the melt with gas. In the gas inlet area of the extruder, it is necessary to maintain the optimum pressure so that the gas is in the right state and has sufficient viscosity and density for dispersion and solubility in the molten polymer. But how does this affect the production process and the quality characteristics of the finished polyethylene and polypropylene foam products?
Photo 1. Production of 5 mm thick physically foamed polyethylene with high and frequent waves
Photo 2. Production of physically foamed polyethylene with thickness of 20 mm with flat smooth surface
Photo 1 shows a 5 mm thick polyethylene foam product produced on a single-screw extrusion line. The material has a fairly frequent and high wave. This is because, in order to pressurize and maintain the required pressure in the gas injection zone of the single-screw extruder, it is not possible to use a sufficiently low pressure at the die outlet of extrusion head and an extrusion head is designed in such a way as to create back pressure in the extruder barrel in addition to the filter screen. This severely limits the production process and makes it practically impossible to produce polyethylene foams with high thicknesses (e.g. more than 12 mm).
3/4. Production of 5 mm thickness low density polypropylene foam with flat smooth surface on extrusion line FAP.
FAP foam extrusion lines (photo 2,3,4) equipped with two screws with counter-rotating movement that allow to create sufficient pressure in the gas inlet zone of the extruder even at extremely low pressure at the die outlet of the extrusion head. In addition, the unique design of the screws of the gas inlet zone allows to change the flow of the melt direction and to create a stronger mixing effect, which in turn allows to disperse the gas in the melt much better and finally to obtain foam with a more homogeneous fine cellular structure (Microcell Technology). All this allows the production of foamed polyethylene and polypropylene both at critically high pressure and at sufficiently low pressure, with a finished product thickness from 0.5 mm to 25 mm, with smooth surface of low-density foamed polyethylene and polypropylene without waves on the same extrusion line. This creates significant advantages in the formation of production costs of finished foam materials for our customers and makes the technology of FAP extrusion lines universal from many sides.
Due to the fact that FAP extrusion technology allows much better and faster cooling of the melt at start-up and adjustment of the extrusion line to the final product, faster and better mixing of colorants and additives due to mechanical contact and the unique screw design, it directly affects the cost of the finished product of polyethylene (EPE) and polypropylene (EPP) foam. Stable production process, with controlled quality indicators, minimizes any risks of hidden defects of finished products, shrinkage of foam during degassing and violation of cell structure integrity, which generally affects production and cost of finished products.
Set-up time of FAP foam extrusion line from the moment of start-up to the first finished roll of EPE foam with thickness of 8-10 mm is on average not more than 65 minutes, which is about 15-20 minutes less than the time required for setting up EPE foam with the same thickness on a single-screw extruder with similar production capacity. This not only saves time and reduces the cost of power consumption, but also reduces the consumption of raw materials in the process of starting the line by 15-20%, affects the reduction of the minimum economically efficient production batch by 10-14%, as well as reducing the cost of placement and storage of products in the warehouse.
The use of foamed polymers is extremely versatile, but the main thing is that all necessary technical requirements are met, specially in construction industry and as a striking example is a reflective insulation. Manufacturers of foamed polymers need to create materials that educate the final user, do not mislead him when choosing products for construction and repair, to force unscrupulous manufacturers to change their approach to production and product quality.
We all want to live in comfort and very often during construction or repair we install a “warm floor” system in our homes. Today, FAP would like to talk about the use of foamed polypropylene and polyethylene in this constructions.
What is reflective insulation for? How can a foam manufacturer not disappoint his customers? Can aluminium foil be used without a protective layer of transparent polymer in construction?
There are some reasons:
• Local overheating of the screed. As you know, the principle of operation of a "warm floor" system is quite simple. Heat from the heating element (water pipes or electric heaters) is transferred to the concrete screed, the concrete screed heats up and heats the coating on it.
It is the reflective layer of aluminum foil that contributes to the uniform heating of the screed and the floor covering, since the thermal conductivity of the foil is about 150-180 times higher than that of concrete and the foil heats up very quickly, evenly distributes heat over the entire space of concrete, without creating local overheating of the floor. The absence of aluminum foil as a reflective layer can cause that in some areas of the floor the heating element warms up much faster and absorb more heat, while in other areas there is no direct contact with the heating element. Ultimately, this can lead to cracking of the concrete screed.
• Reduced heat loss of the “warm floor” construction. PE or PP foam insulates the entire structure, preventing the heat goes down, since the coefficient of thermal conductivity of PE and PP foam with a thickness of 4-5 mm and a density of 25-30 kg/m3 is about 0.035 - 0.038 W/m2, which is approximately 1.5-2 times lower than that of concrete.
Many people mistakenly believe that it is the reflective foil that prevents the passage of heat down, acting as an insulator, but this is not correct. Unfortunately, even builders who have no idea about the principle of this action use only one aluminium foil as insulator without foamed polymer layer. As explained before, the thermal conductivity of aluminum foil is very high and it cannot be used as an insulator without having an air gap underneath, which is foam. Anyone who responsibly attended physics lessons at school has already understood that the foil fulfills exclusively the principle of convection and radiation.
Thus, the use of PE & PP foam with a reflective foil layer with a thickness of only 25-30 microns will significantly increase the efficiency of the "warm floor" system, reduce the heating time of the concrete screed and reduce heat loss.
The fact is that the reaction of an alkaline solution (cement) with aluminum leads to its destruction due to the displacement of hydrogen. After a while, the foil will simply dissolve and only the foamed polymer will remain. For this reason, there will no longer be a uniform distribution of heat over the concrete screed, which can lead to local overheating and cracks. Therefore, it is extremely important to use a foil with a protective polymer layer on the reflective side in the lamination of foamed polypropylene or polyethylene, since the protective polymer layer will not allow the reaction between the foil and the alkaline solution.
Physically foamed polypropylene or polypropylene foam (further on EPP) is an excellent material for civil engineering, automotive and food industries. EPP is a much more “crystalline” material compared to the more amorphous low-density polyethylene foam (LDPE foam), allowing this material to replace a large number of rigid foams on the market.
Due to its excellent physical and mechanical characteristics, the possibility of use in environments with high operating temperatures (up to +130 degrees Celsius), much greater environmental friendliness in contrast to cross-linked polymers and many other types of insulating materials, this type of insulating materials is increasingly attracting the interest of consumers.
Unfortunately, today we see that manufacturers of physically foamed polymers are reluctant to launch EPP into their productions, since they do not have the technology knowledge for producing this product. Additionally, extrusion lines (in the most cases single screw) used to produce polyethylene foam for packaging are not capable to produce a high-quality polypropylene foam material.
Here in FAP we contribute to the development of EPP in the global market. In addition to our foam machineries, we provide training for foam polymers producers, providing a full range of services for calculating production indicators, launching the production of EPP and EPE, preparing all technological and technical documentation.
There is no point in comparing non-crosslinked physically foamed polyethylene (EPE) with physically foamed polypropylene (EPP), since these materials are completely different in performance characteristics.
But we will look at some comparative characteristics of EPP and physically cross-linked polyethylene foam (further on XLPE), since the last one is closer in performance characteristics to EPP.
It can be seen that in terms of the comparative characteristics of thermal conductivity, elastic modulus and application temperature, EPP is superior to XLPE. Does this mean that EPP can replace XLPE in all applications? Of course not.
XLPE has excellent shock-absorbing properties, are much more elastic materials, have the same low thermal conductivity and a number of other qualities that differ from non-cross-linked polypropylene foam, which are necessary in some industries.
Global Goal
One of the main tasks of the global community today is to create a closed-cycle industry and introduce easily recyclable materials into our daily lives.
Physically and chemically cross-linked foams (XLPE) are very difficult and expensive to recycle, and the process is poorly organized. As EPP can be recycled by a rather simple granulation process and can be reused a large number of times. This fact creates closed-cycle production or closed-loop manufacturing, where all waste generated during the production process does not end up in landfills, but is very easily recycled internally in companies and used more times in the same foam manufacturing with different persantages. In addition, the production process of EPP is simpler and more efficient compared to the production of XLPE.
Due to its superior characteristics described above, physically foamed polypropylene (EPP) is set to become a leading material in the following areas:
Insulation in construction:
Insulation in the car interior:
Food industry:
We have already talked about the possibilities and advantages of using EPP in single-use tableware and the reflection of thermal insulation in the “warm floor” design in our articles and posts. In this article we will consider exclusively those qualities of physically foamed polypropylene (EPP) that are necessary for using insulation under high loads and in environments with high operating temperatures.
The issue of sound insulation always concerns the floor of the room in building. In the most countries there is a strictly established standard (the permissible number of decibels transmitted through floor structures). To meet this standard, when building or renovating constructions, it is important to ensure that the floor is insulated as much as possible from airborne and impact noise.
In the construction of the so-called “floating floor”, a variety of insulating materials are used from chemically and physically cross-linked polyethylene foam to polypropylene foam, foam rubber, stone wool, as well as non-cross-linked polyethylene foam.
Physically foamed polypropylene (EPP) is the best way to soundproof a floor under a cement screed.
Below are the results of the durability test "12 months under a load of 2000 N/m2", which shows the change in the thickness of sound insulation from foamed polypropylene (EPP) and cross-linked polyethylene (XLPE) over 12 months.
From the diagramm above we read that the stabilization of the thickness of physically foamed polypropylene (EPP) occurred at the end of the third month, and the loss of thickness at the end of 1 year was 10-11% of the original. Stabilization of the thickness of the crosslinked polyethylene foam (XLPE) occurred at the end of the fifth month, but the overall thickness loss was 20%.
Thus, after a year, the impact noise reduction rates for physically foamed polypropylene (EPP) decrease by approximately 4%, for cross-linked foamed polyethylene (XLPE) by 10%.
Decreasing impact noise reduction results in increased sound transmission through the floor in the room.
Another useful property of EPP, it can be used at high ambient temperatures, where the vast majority of polymer materials are not able to maintain their physical properties. Insulating a sauna is one of the most common ways to use insulation made from physically foamed polypropylene (EPP). This can also be the insulation of a metal roof in countries with large differences in average annual temperatures (Italy, Spain, Egypt, etc.), when in summer the temperature of a metal roof can reach +90-95 °C.
Below are the shrinkage test results of physical polypropylene foam (EPP) and cross-linked polyethylene foam (XLPE) under various temperature conditions for 48 hours.
Please note that after the use temperature exceeds 105 °C for a long time of use, XLPE begins to deform quite severely.
As for physically foamed polypropylene (EPP), it can be used in conditions of constant high temperatures up to 125-130 °C, which gives this type of insulation additional advantages.
The production of this unique material is safe and environmentally friendly, which is one of the most important factors. Due to its molecular structure and a number of other qualities, EPP is quite easy to produce using carbon dioxide as a foaming agent, which creates additional value for this product.
We are confident that expanding the use of non-cross-linked Polypropylene Foam on the market replacing a number of difficult-to-recycle materials will allow to make our planet much better.
FAP Srl is a member of AMAPLAST Italian Plastics and Rubber processing machinery and
moulds manufacturers’ association.
