Foam Technology


PPI is actively involved in the development of high performance foam products from various polymers (PS, LDPE, HDPE, PP, PET, cellulosics and biopolymers) utilizing both chemical and physical blowing agents, such as CO2, N2, hydrocarbons, HCFCs, NaHCO3 etc.  PPI’s foam production capabilities are:


Batch Foaming:

Currently PPI is capable of production of sheet foams with various densities using chemical and physical blowing agents.  The foamed sheets can later be thermoformed into desired shapes.


PPI owns 3 hydraulic presses, capable of maintaining 2200 psi gas pressure and equipped with rapid PLC temperature controllers, and varioussingle and multi-cavity molds (with max 18”x18” sheet size).


Continuous Foaming:

Various extrusion systems are available for production of low/medium/high density foams:


·    Tandem line extrusion (low density foam) 

·    Single screw extrusion(medium and high density foam) 

·     Seven layer co-extrusion line  (medium and high density foam)


Expandable Beads and Molding Technology:

A sintering unit which consists of a steam generator and various molds is used to produce a variety of products (EPS, EPP, etc.) from expandable beads.  Seamless and complex geometries can be produced using this technique where no secondary process, such as thermoforming or welding will be required.


In addition, PPI owns a unique technology to produce expandable beadsfrom various bulk polymers.   


On-line Polymer-Gas Property Measurements


·     Solubility of gas in polymer melt  

·      Viscosity of two phased mixtures (Helical Barrel Rheometer)


Foam Characterization


·     Off-line solubility measurements 

·      Mechanical and Thermal Properties 

·      Rheological Properties 

·      Cell Size Distribution



                    For more information, please contact

Dr. Niloufar Faridi
(973) 596-5665

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