April has already arrived, which means we are here to tell you about our fourth core value: Efficiency - is not just a matter of speed - it is a conscious choice, a way of thinking and acting that defines HOW WE WORK at FAP.

In the world of industrial machinery, where every second counts, we have learned that true efficiency is made of PREPARATION, RESPONSIBILITY, & ATTENTION TO DETAIL. It is about optimizing every stage of the process. And above all, it’s about respecting people’s time: our clients', our partners', and our team’s.

In FAP, efficiency is a way of working and a way of being. It means being present, responding quickly, and acting with clarity and purpose. In a competitive and fast-moving industrial world, we believe that availability and responsiveness make all the difference.

We offer effective solutions, and always give the smart answer at the right time. For us, efficiency is not just speed - it’s about DELIVERING VALUE.

Here, our 'technical' icon of EFFICIENCY transforms into a small work of art.

Efficiency as availability

Efficiency begins by being there when our clients and partners need us. From the first contact to after-sales support, we make sure that questions are answered promptly and that our team is easy to reach and ready to help.
We know that our clients’ time is precious. That’s why we act quickly - without ever compromising on quality.

Efficiency as internal organization

Behind every solution we offer is a coordinated and well-structured team. We promote a culture of clarity and accountability, where each role is well-defined and priorities are shared. This allows us to optimize time and energy, internally and externally.
We work with clear goals and streamlined processes, so that every project progresses in an effective, timely, and accurate way.

Efficiency as a shared value

We bring this mindset into every relationship - with clients, suppliers, and colleagues. We aim for results, not just actions. Furthermore, we know that true efficiency is built on preparation, organization, and mutual respect. Because being efficient means being reliable.

Efficiency for Our Clients and Partners

Fast, Clear, and Reliable Communication. We ensure every client receives rapid, accurate, and useful information. Questions are answered without delay, and solutions are proposed with clarity. Our partners can rely on us to move quickly and keep every interaction smooth and efficient.

Commitment to Timely Delivery. We plan carefully and execute precisely to meet agreed deadlines. From custom machinery to technical support.

Long-Term Collaboration Built on Responsiveness. Efficiency builds trust. Our clients know they can count on us not just for quick replies, but for consistent follow-through.

These values are not just principles - they are the way we work, every day.

In previous months, we introduced three other core values of our daily approach:
• Flexibility, our ability to adapt to the needs of each project and each client.
• Listening, the attention we give to those who work with us and rely on us.
• Integrity, the transparency and consistency that guide our words and actions.

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We’re excited to announce a live webinar happening on April 10, 2025. Don’t miss this chance to gain valuable insights, ask questions, and connect with experts from FAP, Borealis and Royce Global.

The industry leaders will reveal how FAP the latest CO2 foaming equipment, Borealis HMS PP Daploy™ 140HMS, and Royce Global functional additive masterbatches are transforming EPS foam production to improve both sustainability and efficiency. Through real-world case studies and expert insights, you’ll gain actionable strategies to enhance your performance, meet regulatory requirements, and reduce your environmental impact.

Meet the experts leading the change

Denisa George (Borealis) will explain how regulatory trends are pushing the shift toward eco-friendly foam solutions.
Francesco Poli (FAP) will introduce FAP’s groundbreaking CO2 foaming twin screw counter rotating extruders and its impact on efficiency and product consistency. 
Sean Wilson (Global Royce) will reveal how functional additive masterbatches optimize production and enhance foam performance. 
Antti Tynys (Borealis) will showcase the power of Polypropylene and its potential to revolutionize packaging, insulation, and other foam applications.

With the industry evolving fast, this webinar is your chance to stay ahead, gain insights from top industry leaders, and take part in the conversation that’s shaping the future of sustainable foaming.

Register Now!

Save the date and join us online!

Competitive advantages of FAP foam twin-screw extrusion technology

Improved dispersion of gas in the melt

One of the main processes in the production of non-cross-linked physically foamed EPE, EPP, EPS 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 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 changing the flow of the melt direction and to create a stronger mixing effect, which in turn allows dispersing 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.

The impact of FAP twin-screw extrusion technology on the cost of the end product

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), polypropylene (EPP) foam and polystyrene (EPS). 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.

Advantages of FAP Twin Screw Counter-Rotating Foam Extruder

FAP always analyses the customer's needs in detail from all sides when developing and designing foam machinery. FAP grows and develops together with its clients.

To all the remarkable women in our lives 🌸 Today, we celebrate the incredible strength, resilience, and achievements of women everywhere.

Today, we honor the strength, resilience, and achievements of women everywhere.

A special recognition goes to the dynamic community of Women in Plastics (WiP) Italy - a thriving association of women making waves in the plastics industry. Together, they are breaking barriers, fostering innovation, and paving the way for a more diverse, inclusive, and sustainable future 💚

Women in Plastics represents a powerful collective of professionals dedicated to being a voice for the female perspective in the industry. By uniting their talents and expertise, they are creating a vital platform to inspire and drive meaningful change.

Here’s to celebrating women, empowering progress, and building a better tomorrow 🌍

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In today’s world, integrity is a word often spoken but rarely practiced. Transparency has become an exception rather than the norm, and trust, once the foundation of business, is now a fragile commodity. Deals are made behind closed doors, promises are bent, and commitments are often broken. Yet at FAP, we choose a different path - one where integrity is not just a principle but a way of doing business.

Integrity in Every Action

Integrity is more than keeping promises - it is about delivering on them with precision, transparency, and accountability. Whether we are designing a custom foam extrusion line, advising a client on the right solution, setting realistic delivery timelines, or even acknowledging when we don’t have an immediate answer, we act with honesty and fairness. We believe that truth builds trust, and trust is the foundation of long-term success.

Integrity with Our Team

Integrity begins within. At FAP, we cultivate a culture of respect, inclusion, and ethical responsibility. We foster open communication and a sense of ownership, empowering our people to make responsible decisions. By aligning our actions with our values, we create a workplace where collaboration thrives.

Here, our 'technical' icon of Integrity transforms into a small work of art.

Integrity with Our Clients and Partners

• Honest and Transparent Communication. Trust is built through clarity, consistency, and truthfulness. We ensure our clients receive accurate technical information, realistic timelines, and transparent solutions. This empowers them to make confident, well-informed decisions, knowing they are working with a partner who values honesty.
  
• Commitment to Quality and Performance. Integrity is reflected in everything we build. Every FAP machinery/project is engineered to the highest quality standards, ensuring durability, efficiency, and reliability. Our clients receive solutions that deliver exactly what we promise.

• Partnerships Built on Trust. Integrity is not about short-term gains; it is about building long-term relationships. Our commitment goes beyond selling machines—we are partners in growth, providing ongoing support, upgrades, and insights to help our clients stay ahead in an evolving industry.

• Ethical Responsibility in Innovation. Innovation without integrity is meaningless. Every advancement at FAP is made with the goal of genuine improvement, not inflated claims or exaggerated promises. We innovate not just for the sake of progress, but to create solutions that are truly valuable, reliable, and beneficial.

Integrity: The FAP Way

At FAP, integrity is not just a word - it is how we work, communicate, and grow together. It is the force that binds us to our clients, our team, and our partners. In a world where trust is scarce, we choose to stand firm in our principles, proving that ethical business is not just possible - it’s the only way forward.

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How much does it cost to produce an item?

To find it out, we have to consider: administrative costs; production costs; warehouse costs.
In this article, we will consider production costs, specifically those costs necessary to produce final products from expanded polyethylene (EPE) and polypropylene (EPP) foam.

The relevant factors to consider are:

1. Raw materials (usually represent 45-55% of the total cost of finished products)
2. Logistics (warehouse and storage)
3. Energy costs
4. Work productivity indicator

Market slowdown: cutting operating costs and reducing quality

The polyethylene (EPE) and polypropylene (EPP) foam processing sector is slowing down; some, even speak of oversaturation of the offer. To overcome this problem, manufacturers have often chosen to act on quality by: reducing product density, reducing nominal thickness, choosing low-cost raw materials. This strategy has enabled them to survive in the short run but cannot be considered a solution.

Solution: New processes to increase efficiency and reduce production costs

A key factor in the overall calculation of production costs for expanded materials such as polyethylene foam (EPE) and polypropylene foam (EPP) is the choice of equipment and process technology.

Reducing raw material costs with FAP’s twin-screw foam extrusion technology

Using low-cost technology may seem convenient, until we quantify how much it costs a company to produce 1 sqm of defective product.

An efficient production technology must guarantee:
- line start-up speed
- change of raw materials during the production process
- short time to change production parameters
- simplicity and precision of the line process control

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Production advantages of FAP foam technology

In order to provide a technological advantage in production, FAP engineers design our lines with 4 fundamental characteristics:

• Dosing station

Equipped exclusively with independent gravimetric dosing units with a dosing accuracy of 0.3%, for the best control of the recipe (for checking the cost of raw materials per unit of product). The station is able to guarantee the change of any component during the production process in 7 minutes max. (for the minimization of production waste).

• Optimising warehouse stock management

Reducing production waste allows reducing inventories, increase stock turnover and obtain cost-effective batches, thus reducing product storage costs.

• Reducing the risk of overproduction

The twin-screw counter-rotating FAP foam technology significantly reduces:
- the risks of foam shrinkage due to the disruption of its cellular structure;
- bubbles on the foam material due to thinning of the cell walls;
- excessive gas expansion.

This eliminates the risk of products "overproduction", which would also affect their storage costs.

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FAP extrusion lines: increasing energy efficiency

The cost of energy is rising: in many countries, in recent years, it has doubled. It is evident that this item has a great influence on production costs. This is why FAP complies with the highest and strictest energy efficiency standards by designing with specific attention:

- the heating elements: FAP extruders are shorter and more compact than single-screw extruders and consume 25-30% less electricity to heat the cylinder;
- the main motor: ABB's unique SynRM jet-rotor motors with energy class IE5 provide high specific power and torque and low winding and bearing temperatures, thus reducing energy consumption by 25-30% compared to standard induction motors;
- the gearbox: the modern Zambello ZT3 gearbox guarantees a high transmitted torque density (up to 17 Nm/cm3 per shaft).

FAP foam extrusion lines are some of the most efficient in terms of energy consumption per unit of production and provide huge cost savings.

Automation of FAP extrusion lines increases productivity and efficiency

Industrial automation processes are more important today than ever before: production lines must be intuitive in order to simplify the training of operators and quickly train new ones, but they must also be able to independently (automatically) perform numerous technological tasks.

The automation of FAP foam extrusion lines can be implemented in modular way and allows you to:
- visualize the progress of the production process in real time;
- receive control alerts;
- operate with automatic winding systems with soft winding technology;
- take advantage of systems for the automatic removal of the roll from the rod and for the automatic application of glue to the core.

By minimizing the number of operations on the line performed directly by operators, it is possible to significantly increase labor productivity in production, thus positively influencing the cost of finished products.

FAP is efficiency and performance

Listening is not just a skill; it’s a commitment. It’s the way we connect with our clients, partners, and team, ensuring that every need, challenge, and idea is heard and acted upon.

At FAP, listening is more than hearing words - it’s about truly understanding the unspoken needs and expectations. This philosophy shapes the way we approach every project, driving innovation and creating lasting partnerships built on trust and collaboration.

Here, our 'technical' icon of listening transforms into a small work of art.

But what are the concrete benefits for FAP clients and partners?

1. Understanding Needs for Tailored Solutions
   Each FAP project begins with a deep dive into the client’s production goals and challenges. Through active listening, we design solutions that are not only efficient but also perfectly aligned with their specific requirements.
   
2. Enhancing Production Efficiency
   By listening carefully to feedback and market trends, FAP consistently optimizes its machinery, ensuring that clients benefit from cutting-edge technology tailored to their evolving needs.
   
3. Building Stronger Partnerships
   Active listening is the foundation of long-term relationships. FAP partners with clients to provide not just machines, but ongoing support, ensuring mutual growth and success.
   
4. Empowering Internal Collaboration
   By fostering a culture where every voice is valued, the team collaborates effectively, driving continuous improvement and fresh solutions.

At FAP, listening is more than a value - it’s a philosophy that drives us forward. By putting this into practice, we not only meet expectations but exceed them, helping our clients succeed in a competitive global market.

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• Low automation of production processes.
• Bubbles, foam collapse, layer delamination during lamination, a lot of defects during production line setup.
• Degassing period, low warehouse turnover, the share of logistics in the cost price can be 18-23%.
• Lack of intellectual base and resources for developing new types of products.
• Big problems with qualified personnel.
• High costs of raw materials - the share of raw materials in the cost price is from 45 to 55%, therefore any price increase significantly increases the cost price of products.

Specific solutions from FAP division Italian Foam Centre

Challenge 1 - Technological Defects and Poor Quality of Foamed Polymers?

• Destruction of the structure and bubble formation on the foam surface during degassing? 
• Low adhesion of foamed polymer and peeling of layers after lamination? 
• High percentage of defects per batch during extrusion? 
• Low compressive strength, poor thermal stability, insufficient tensile strength, or other unmet required parameters? 

Solution 1 by Italian Foam Centre:

• Optimizing production process parameters through detailed analysis and specific recommendations for each type of processing additive. 
• Developing and implementing copolymers in the production formula to enhance adhesion. 
• Minimizing technological defects by improving technology and production processes. 
• Enhancing the physical and mechanical properties of expanded polymers to meet customer requirements. 

Challenge 2 - Struggling with High Raw Material Costs?

• Looking to reduce product density without compromising production stability?
• Unsure which raw materials to select for your specific product?
• Wondering if it’s possible to produce physically foamed ultra-low-density polyethylene?

Solution 2 by Italian Foam Centre:

• Conducting in-depth analysis of raw materials and equipment to optimize production costs.
• Developing tailored raw material specifications based on the type of product being manufactured.
• Proposing advanced technological solutions for producing physically foamed polyethylene with the lowest possible density while ensuring a stable production process.

Challenge 3 - Developing New Foamed Polyethylene and Polypropylene Products?

• Need to create a product that stands out against other polymers?
• Lacking knowledge of raw material compositions?
• No access to testing facilities?
• Ready to bring your product to market?

Solution 3 by Italian Foam Centre:

• Innovating new types of expanded polymers, including the blending of different polymers to introduce new properties.
• Developing the raw material base with detailed cost analysis tailored to your technical specifications.
• Testing production processes in FAP’s dedicated laboratory.
• Evaluating the product for compliance with the required physical and mechanical properties as per technical specifications.
• Providing comprehensive marketing support to promote your product within the packaging and insulation markets.

Challenge 4 - Advanced Training for Engineers and Operators in Polymer Foam Production

• Need to enhance the skills of your production team in polymer foam manufacturing?
• Looking to reduce human error rates in production?

Solution 4 by Italian Foam Centre:

• Developing comprehensive training materials for an in-depth understanding of physical foaming
• Organizing and conducting practical, hands-on technological training directly at your production site.
• Creating process documentation and operating procedures that align with the quality management system.

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Flexibility is the first of the 12 values outlined in the FAP MANIFESTO.

In the calendar that FAP distributed for Christmas, flexibility is defined as a mindset that characterizes the way each member of the team approaches their work.

“We are quick to adapt to changes and respond to the needs of the context,” says Karina, the company’s Marketing Manager. “For us, being flexible means listening to the requests of clients and partners and finding customized solutions that meet their needs, while maintaining the agility necessary to compete in an evolving market. Internally, we promote an open mindset, encouraging our team to be versatile in their activities and to respond promptly to new challenges. Client needs can change rapidly, and being flexible is not just an added value - it’s an absolute necessity.”

FAP has made flexibility one of the cornerstones of its business strategy, demonstrating that adapting to specific client requests creates real value. The ability to customize machinery to meet production requirements allows the company to be a partner in efficiency and optimization.

Here, our 'technical' icon of flexibility transforms into a small work of art.

But what are the concrete benefits for clients?

1. Tailor-Made Solutions
   Flexibility enables FAP to deliver systems that perfectly align with clients’ production needs and technical constraints. Every project is the result of an in-depth dialogue, where understanding the client’s requirements is paramount. This approach not only ensures the fulfillment of specific requests but also optimizes production processes.
   
2. Continuous Innovation
   Flexibility also means being ready to integrate the most advanced technologies to meet new market challenges. FAP consistently invests in research and development, ensuring that its clients receive cutting-edge systems that improve efficiency and reduce operating costs.
   
3. Quick Response Times
   Thanks to an agile organizational structure, FAP responds swiftly to requests for technical and technological support, maintenance, or system upgrades. This translates into an operational advantage for clients, who can rely on a dependable partner always ready to assist.
   
4. Operational Versatility
   FAP’s machinery, including extruders, laminators, and cutters, is designed to be easily adaptable to various applications and materials. This allows clients to diversify their production, increasing competitiveness in the market.

Flexibility is a tangible promise that FAP delivers on every day. Through this philosophy, the company not only meets its clients’ needs but helps them grow and thrive in an increasingly demanding global market.

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FAP starts 2025 with a journey through the 12 values of the FAP MANIFESTO, the cornerstone of its brand identity. In a dedicated series of news updates, FAP will explore the values that make its brand unique, guiding readers through an engaging reflection on the world of foam and flexible film machinery.

Each value is accompanied by a dedicated illustration, crafted to represent its essence. These distinctive icons, designed in true "FAP style", highlight various thematic areas and are integrated into our institutional communications. You’ll find these icons in our official materials, such as when you visit us in October at the K2025 Trade Fair in Düsseldorf, Germany.

Yet, technology is also about creativity, and imagining is the first step toward innovation. Our “technical” icons transform into small works of art, capable of conveying the same concepts in an imaginative and evocative way. You’ll find this artistic version of our values on our social media platforms and, of course, here in the news section of our website.

This journey is not just a way to tell our story, but also an opportunity to inspire, demonstrating how technology and imagination can work in harmony to innovate and shape the future.

Stay tuned to discover, month by month, the values that make FAP a unique and visionary partner.

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