FAP does not only produce advanced equipment for foam, our team also loves getting immersed into the process of physical foaming of polyethylene and polypropylene.
We also share our experience with our clients and partners, trying to teach everything we know and study ourselves. Spending a huge number of hours in our laboratory, we study all the nuances to make the technological process of foaming as simple and safe as possible for you.
Today we will analyse two rather serious hidden technological errors in the production of polyethylene (PE) and polypropylene (PP) foam, which are not visible at first glance but can significantly affect the quality of products, the formation of defects and the efficiency of your production.
As for any kind of foamed polymers, physical foaming has its own nuances, and one of them is changes in the gas density in the polymer during and after foaming (expansion) due to its solubility.
Yes, after the production of the finished material, the expansion continues, since the gas is still hot and continues to expand. If this process is not properly controlled, it leads to many problems associated with the formation of cell wall destruction, the formation of bubbles on the material and, of course, the deterioration of its physical properties and its mechanical characteristics.
We know that many pipe insulation manufacturers have to face the problem of changing the internal diameter of the finished product due to wall expansion and subsequent deviation from the nomenclature requirements. Instead in the production of a packaging profile, the problem of excessive expansion can lead to a loss of profile geometry and, as a result, to the impossibility of using it due to poor fit. This will be a particularly big problem in the production of complex shaped profiles from physically foamed polyethylene, where it is necessary to achieve the most accurate geometric dimensions with minimal tolerances for deviations. The market is going in this direction very strongly and it would be very right strategy to compete in the field of complex figured profiles with the manufacturers of cross-linked foams XPE.
We faced a similar situation at one of client's factories, in the production of foamed pipe insulation, where during the degassing process the geometry changed either up or down, and the quality department often rejected entire batches of products. In this situation, the problem was solely in the wrong technological documentation, as well as in the methods of production and storage, since at another plant in the same region, operating on similar raw materials and identical equipment, such problems were reduced to almost zero.
What is the first reason of this main problem? The first and very serious error is that an improperly developed homogenization and melting process leads to excessive expansion of gas.
And this is a very big problem, especially in the production of foam insulation with complex shapes and tolerances or foam insulation, where a high modulus of elasticity is needed. We will not go into detail now on how this error affects the modulus of elasticity and sound insulation characteristics, if you need more information, you can contact to us.
The second reason follows from the first: overheating of the polymer mass and gas further increases the migration of GMS to the foam surface, creating an additional barrier to diffusion during the maturation of the foamed polymer.
This problem is 50% a consequence of the first technological error described above. The finished product (physically foamed polyethylene or polypropylene with gas like isobutane) requires a certain amount of time in the warehouse after manufacture before further use.
The degassing period depends on the thickness of the material, its density kg/m3, the number of meters in a roll, the temperature and humidity of the environment, the concentration and dosage of GMS, and the air exchange in the warehouse. The first and essential factor in the process of replacing gas with air is the migration of GMS to the surface of the foamed polymer.
This process occurs in any case, because GMS:
But with the wrong choice of GMS with a very low processing temperature and the wrong choice of melt and homogenization mode, you will greatly enhance this effect. This can be seen by the formation of a film or "crust" on the surface of the foam sometime after production, especially on foam with a small number of GSE (cells) per 1 cm2 and with large cells. This is due to the fact that, while migrating to the surface, GMS freezes, forming this same film and “crust” on the entire plane of the material, significantly complicating the degassing process.
We did a small test to see how the emulsifier volume affects the degassing rate on polyethylene (PE) foam of 4 mm and 10 mm thickness with a density of 18-20 kg/m3, adding GMS at 2% and 1.2% of the total throughput. The results confirmed the fact that a decrease in the GMS concentration leads to a faster replacement of gas by air by 20.2% due to a decrease in its concentration on the foam surface.
Of course, reducing the dosage of GMS is not the best way to shorten and normalize the terms of gas exchange and reduce the pressure inside the cell, we only focus your attention on the correct choice of GMS, its concentration, formulation and processing temperature in the process of foaming in order to prevent excessive migration of GMS to the surface of the foam and excessive pressure of the expanding gas in the cell of the foamed polymer.
In addition, the storage conditions of polyethylene (PE) and polypropylene (PP) foam can also adversely affect the degassing period. Our tests on various materials with a thickness of 2 mm, 3 mm, 5 mm and 10 mm with a density of 18-20 kg / m3 show that the optimal temperature regime for storing foam finished materials of polyethylene and polypropylene is from 18 to 23 °C at a humidity of 30-40%.
For example, the degassing period (replacement of gas with air) of material in the form of rolls at a storage temperature of +10.3°C and a humidity of 38% is on average of 41.7% slower than the rate of degassing of a similar material during storage at +18.6°C and 30% of humidity.
Thus, an excess of residual gas significantly affects the further process of lamination of polyethylene and polypropylene foam with each other.
The fact is that when the foamed polymer is heated and melted with an air blade and a hot roll, the gas leaves the cells and expands sharply between the layers during lamination, preventing high-quality adhesion. Moreover, delamination may not be immediately noticeable, but occurs after a few hours as the gas expands and pressure is created between the layers.
Birth of new FAP VELA brand: resumption of designing and machine construction with full technical service for Vela’s customers.
FAP has always been inspired by the versatile solutions of the Spanish company Vela which represents the surname of its founder and inventor. Due to this fact the new FAP VELA brand was born: the union of their passions for high-performance and intuitive solutions and international experience. This fusion will allow to approach the market with the extension of the new range of solutions, which are extremely versatile machines for the packaging sector:
| Cutting machines for the production of sheets in bubble film and foam sheets from rolls. The versatility allows it to perform a wide, processing different sizes materials. No damage of the material. | Welding machines for the automatic production of different size of bags in bubble film and foam. It features a stacking system that does not damage the material. | Folders the preparation of rolls, transform a plain material into two half-tubes with mechanism of folding: high quality and a large batch production of bags. |
FAP presents the new FlexCut16 cutting machine
FlexCut16 is SHEET CUTTER MACHINE - A HIGHLY VERSATILE & FUNCTIONAL SOLUTION FOR THE PRODUCTION OF SHEETS / FORMATS from bubble wrap and foam.
Its versatility allows to perform a wide variety of functions, processing different sizes, thicknesses and materials. The machine produces a regular cut with great precision in the size of the format. It features a stacking system that does not damage the material.
✔ Fully automatic
✔ High production capacity
✔ High quality of the finished product
✔ User-friendly operation
Beneficiary: FAP SRL
Project management by: Politecnico di Milano
Finally FAP's long and rich international experience is at the complete disposal of the entire FOAM WORLD.
Thanks to foam extruder in our internal laboratory together with our customers, raw material producers and research centers, we create, test, approve new solutions capable of anticipating the ever-changing foam market demand or even changing the competitive scenario.
We dedicate ourselves daily to the development of innovative technologies and to the study of new fields of application of polyethylene (PE) and polypropylene (PP) foam (expanded films).
Laboratory foam extruder is a perfect copy of FAP extruders of industrial scale with “direct gazing” technology and high performance characteristics. The foam extrusion line has nr.3 (three) extrusion dies (heads): round, flat, tube/pipe.
Researchers, producers of raw materials, producers of foam materials and start-up businesses are welcome to discover the benefits of FAP technology:
Three years ago exactly Luigi Poli, the founder and father of FAP, passed away.
He was always passionate about his creation, his machines, cared for and controlled down to the last detail. He was always present with customers during the start-up of the lines because he considered them as his own children whom he accompanied on the greatest adventures to conquer the world's markets.
From the 1980s, he was able to lead FAP from the production of simple packaging machines to complete production lines for expanded film and turnkey factories.
His memory is always alive, in the passion and dedication that his sons Francesco and Fabrizio Poli and the entire FAP team put into their work every day, but also…
Dear Customers,
More than 25 years have passed since I started building plastic processing machines. In this long period of time, FAP has gained such experience that have been able to complete the range of our industrial plants and offer our customers an important technical and commercial support, with a very high level of customization.
Our creations cross national and European borders, but our production facility is still located in Brianza, one of the most important industial areas in Italy. This is where FAP's production heart beats, and it is here, with the help of my two sons Fabrizio and Francesco, that we will continue to make our desire to do OUR JOB WELL available to our customers, old and new.
Luigi Poli
We are aware about the coming restrictions on PS foam packaging trays and containers widespread in the food industry, and today we are proud to offer our high technological solution for companies which facing with this problem.
According to the numerous requests, ITALIAN FOAM CENTRE have found and approve the safe solution to offer to companies which have to switch over to EPP production or want to start a new one.
We are proud to share that in our foam centre has been produced excellent samples of PP foam (density 120 kg/m3 , thickness 1mm) totally recyclable and perfect to be thermoformed in food trays or used for other applications in any industrial field. The safe production of polypropylene foam (EPP) samples was carried out using natural CO2 gas, which is directly injected into the extruder during the extrusion process by special systems.
We are continuing to improve, develop and carry out different tests also by requests from our clients.
Stay tuned to find out more!
For more information send your request by e-mail sales@fapitaly.com.
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!
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: sales@fapitaly.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.
FAP Srl is a member of AMAPLAST Italian Plastics and Rubber processing machinery and
moulds manufacturers’ association.
