Foam and Bead Extrusion

Foam extrusion systems for consistent quality

In foam extrusion, maximum efficiency and product quality are critical for competitive production. KraussMaffei Extrusion offers high-performance foam extrusion systems engineered for flexible processing and reliable operation. This provides you with consistent product quality and efficient production tailored to your requirements. Our solutions enable high output rates at low densities while ensuring consistent product quality. With our expertise, we support your production goals with efficient, stable, and performance-oriented extrusion processes.

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Applications

Foam boards

In insulation and new energy applications, foam board processing using physical blowing agents is widely applied. These systems are typically based on XPS, PET or PP. KraussMaffei Extrusion enables process solutions for foam extrusion, board shaping, and surface finishing. This supports products with defined thermal efficiency, structural stability, and precise dimensional performance for your requirements.

EPS foam boards

Particle foams, primarily based on EPS beads, are extensively used in insulation and packaging applications, with additional potential depending on specific requirements. Processing typically includes bead expansion, molding, and finishing steps. KraussMaffei Extrusion provides process solutions that enable defined shape accuracy, density control, and performance characteristics for your applications.

Foam sheets

Foam sheets with physical blowing agents are produced using circular die technology. The tubular web is cut, laid flat, and finally wound into rolls. These PS, PE and PP foam sheets are commonly used in packaging and building applications. KraussMaffei Extrusion offers process solutions for stable production and defined product quality for your specific application requirements, ensuring consistent results and reliable processing performance.

Foam tubes and profiles

Foam tubes and profiles with physical blowing agents are manufactured to meet specific customer requirements. They enable tailored geometries and dimensional specifications for a wide range of applications. KraussMaffei Extrusion delivers process solutions that ensure stable processing conditions and consistent product quality. This offers precise adaptation to defined functional and design requirements.

Processing Options

Mixaco Container
Mixer

Koch Technik Hot Air Dryer

Our Process

Upstream Processing

Before processing, raw materials are analysed in our laboratory for moisture content, bulk density, and other relevant material properties.
High-precision gravimetric dosing ensures consistent and accurate formulations.
Blowing agents are introduced via pumps or dedicated dosing units, enabling precise control of foam expansion and stable material properties across the process.

Extrusion

Material is first fed into the twin-screw system, where optional vacuum degassing can remove volatile components. Blowing agents are then introduced and homogeneously distributed within the melt during intensive mixing. The process continues in the KME single-screw cooling system, where the blowing agent dissolves into the melt under controlled conditions, followed by further cooling to ensure stable and consistent material quality.

Forming and Downstream Processing

Foaming is carried out in foam dies of various geometries or through pelletizing into particle foam.
Profiles and boards are cut to defined dimensions and prepared for further processing.
KraussMaffei Extrusion delivers process solutions for packaging applications, including optional coating of particle foams to meet specific functional requirements.

Logistics

KraussMaffei Extrusion manages the entire logistics process – from worldwide shipping to onward transportation for downstream processing steps. Whether by land, air or sea, or via on-site collection, we reliably coordinate the transportation of machinery, plastics and rental equipment according to your requirements and ensure their integration into customized process engineering systems. With fully digitalized, SAP EWM-supported processes and integrated hazardous materials management, we ensure safe, efficient and internationally coordinated logistics.

Our Products

For more information about our extrusion products, please visit our product pages on kraussmaffei.com.

Co-rotating twin-screw extruder (ZE BluePower)