Foamed sheet

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MEAF 90mm co-extrusion line for (foamed) rigid sheet production
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Main extruder

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Rollstack

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Winding system

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Co extruder

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When facing the challenges of today and in the future when it comes to the reduction of the ecological footprint, such as decreasing of CO2 emissions and reducing raw material (plastic) consumption: Physical foaming technology (by means of Nitrogen (N2) or CO2 injection (and a small amount of nucleator) presents a solution to this challenge.

Extrusion capabilities

Thickness
0.15 – 2.5 mm
Density reduction
Up to 30%
Output
Up to 1500 kg/hr (single layer)
Multi-layer options
Up to 7 layers

Difference between physical foaming and traditional expansion foaming

The first thing that is thought about when we talk about physical foaming are the expandable, low density foamed products made of polymers such as EPS, XPS or even other modified commodity polymers such as EPP or EPE.

With the physical foaming technology of MEAF, we do achieve a significant density reduction (up to 50%) yet the process itself significantly differs from the above mentioned products. The main difference with the expandable technology is that the physical foaming technology adds an environmental friendly blowing agent, N2, into the polymer melt, thereby creating a micro-cellular structure the moment it leaves the die head, which in return causes the density reduction.

The microcellular structure decreases the density of the sheet without compromising on mechanical strength and top load properties. This foamed sheet produced by the MEAF sheet extrusion line can be utilised in packaging solutions (such as meat trays, clamshells or cups for hot fill) but also in industrial and/or electronic applications (such as car interiors, television screens and backlighting).

Physical foaming advantages:

A major impact on the total cost of producing extruded sheet are the cost of raw materials. When opting for a solution made from physically foamed material, the material characteristics of the polymer remains unbroken ( such as rigidity and scratch resistance) with the advantage of 20% less plastic material utilised and an overall weight reduction of 10 – 50%.

  1. Lower material cost (approx. 20%);
  2. Use off environmental friendly blowing agents;
  3. Overall weight reduction up to 30%;
  4. 100% recyclable final product;
  5. 100% use of regrind material possible;
  6. More cost-effective solution than chemical foaming on the long-term.

Foamed sheet extrusion lines key advantages:

  • More output, smaller footprint.

    Requires less space, lowers CO2 emissions, and improves output as much as 100%;

  • Lower energy and production costs

    Reduces energy consumption by 25 to 65% and cuts OPEX significantly;

  • Savings on raw material costs

    Lesser material required due to density reductions up to 30%

  • Environmentally friendly blowing agent

    Nitrogen is used instead of traditional butane or propane

  • Sheet extrusion lines can be prepared for integration of foaming equipment
  • Maximize regrind and recycled content

    Processes up to 100% regrind while maintaining consistent quality;

  • Stable temperature control

    Maintains precise set temperatures even at lower production temperatures;

  • Flexible material handling

    Process multiple polymers using the same screw and barrel—no need for hardware changes.

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