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 – 2.0 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 50%;
  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:

  • Increased output with smaller sized extruders.

    Improved by 20% – 100%

  • Increased energy efficiency

    By 10 – 65 % per kilogram of produced product

  • 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
  • Optimal processing with regrind/recycled material

    Up to 100% regrind

  • Stable pressure at higher outputs

    Minimal flow and pressure fluctuations

  • Multiple materials with same screw and barrel design

    No need to change the screw when changing the raw material

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