Foam Extrusion Systems
Microcellular CO₂ / N₂ Physical Foaming Technology
Promix foam extrusion systems are patented engineering solutions developed for the production of high-quality microcellular polymer foams using environmentally friendly CO₂ and N₂ gases. The technology enables significant weight reduction, lower material consumption and improved product performance without compromising mechanical properties.
The system integrates gas dosing, static mixing, melt cooling and nucleation technologies into a single process architecture to ensure stable foam structure, uniform density distribution and repeatable production quality.
Key Performance Advantages in Foam Extrusion
Promix microcellular foaming technology delivers measurable process and cost benefits:
• Density reduction from 10% up to >70%
• Weight reduction up to 30% depending on application
• Annual cost savings up to €500,000
• Reduced raw material consumption
• Improved thermal and acoustic insulation
• Higher stiffness or improved flexibility depending on structure
• Increased use of recyclable materials
Examples from industrial applications:
• PET thermoform tray → 20% less material
• PS yogurt cup → 15% less material
• PE bottles → 12% lighter
• PP foam core pipes → up to 30% lighter
• PP sandwich boards → approx. 30% weight reduction
Technology Architecture
Promix foam extrusion lines combine several core process technologies:
Gas dosing systems
• High-precision CO₂ / N₂ dosing
• Flow range from <5 g/h up to 12,000 g/h
• Operating pressure 300-700 bar
• Mass-flow controlled dosing
• Automatic "Flow-Match" with extruder output
Gas injection & mixing
• Special high-pressure injectors (up to 1000 bar)
• Static and dynamic mixing modules for homogeneous gas dispersion
Melt cooling & temperature control
• P1 cooling mixer technology
• Precise temperature stabilization
• Higher melt strength for stable foam structure
Nucleation technology
• Tailored nucleation additives
• Optimized die design for uniform cell formation
Process Stability and Foam Quality
High-quality foam extrusion depends on precise control of gas dissolution, temperature and residence time. Promix systems ensure:
• Homogeneous gas distribution in the melt
• Narrow residence time distribution
• Stable microcellular structure
• Improved surface quality
• Reduced process fluctuations
In industrial installations, foam extrusion lines equipped with Promix systems demonstrate stable output and repeatable cell structures even at higher production rates.
Replacement of Chemical Foaming
Physical foaming with CO₂/N₂ provides major operational and environmental advantages compared to chemical blowing agents:
• Investment payback typically < 1 year
• Better cell structure and process stability
• Lower achievable foam densities
• No chemical residue risks
• 100% recyclable production waste
Line Performance and Productivity
Promix foam extrusion solutions improve both production efficiency and output:
• Increased extrusion capacity up to 15-20%
• Reduction of blowing agent consumption by 10-20%
• Faster start-up times
• Lower melt temperatures without freezing risk
• Shorter cooling sections and improved line efficiency
Industrial Applications
Promix foam extrusion systems are used across a wide range of industries and product categories:
Packaging
• PET thermoform trays
• PS cups and containers
• XPS and EPS food packaging
Building & construction
• Insulation boards
• Foam sheets
• Sandwich panels
Automotive
• Lightweight interior components
• Structural foam panels
Extrusion products
• Foam core pipes
• Profiles
• Cable insulation
• Film and sheet extrusion
Multiple installations worldwide demonstrate reliable production for PP, PS, PET, PE, ABS, PA and TPE foam applications.
Installation and Integration
Promix foam systems can be integrated into existing extrusion lines with minimal modification:
• No major extruder screw or barrel modification required
• Retrofit compatibility
• Short downtime during installation
• Flexible configuration for different materials and products
Typical system architecture includes:
Extruder → Gas Injection → Static Mixer → Melt Cooler → Die
This configuration ensures stable gas dispersion and optimal foam formation before die entry.
Why Promix Foam Extrusion Technology?
• Patented microcellular foaming process
• More than 200 industrial reference applications
• Global expertise in mixing, cooling and foaming technologies
• Integrated system approach instead of single equipment supply
• Proven performance in high-throughput industrial extrusion lines
Promix foam extrusion solutions enable manufacturers to produce lighter, more sustainable and cost-efficient plastic products while maintaining superior mechanical and functional properties.
