FAP: Anticipating future trends in foam industry

FAP demonstrates that combining high quality with environmental responsibility is possible and takes pride in contributing to a greener world where sustainability is not just a demand but a reality

Italian company FAP is at the forefront of manufacturing extrusion machinery for polyethylene & polypropylene foam, from conception to creation. Redefining the future of the foam industry, FAP demonstrates that it’s possible to combine high quality with environmental responsibility. FAP takes pride in contributing to a greener world where sustainability is not just a demand but a reality.


One of the serious challenges that industries face today, including polymer foam production, is a serious shortage of personnel, both engineering and process professionals, as well as operators and technicians on production.

Today, it is crucial to design not only reliable equipment that meets all safety standards, but also to pay great attention to automation systems, to create a user-friendly interface, to implement control and process correction systems, to provide customer support at all stages of the project. This is the “efficiency” by FAP and its 4 divisions, which are aimed at increasing the efficiency of production and technological processes, reducing customer losses and opening for the new opportunities in the foam markets.

FAP. Extruders, downstream equipment and converting machines for foam & bubble film. Since 1987 development and assembly of universal extruders, automatic winders, laminating lines.

VELA by FAP. Machines for cutting formats & producing bags (foam and bubble film). Spanish brand VELA’s technology has been part of FAP since 2022.

FAP Automation. Mechatronic solutions of the highest level: automatic machine, industrial robotic islands and collaborative robots in partnership with industry leaders; electrical boards, spare parts.

Italian Foam Centre an absolutely new way to support foam producers in challenging innovative production targets sharing knowledge and innovation with the investors. IFC has an innovative foam twin-screw counter-rotating extruder with a production capacity of 40 Kg/h to create, test, approve new solutions capable of anticipating the ever-changing foam market demand.

Competitive advantage

When a decision is made to invest in foam production, it is important to understand what market challenges are being addressed and whether the end product will be competitive.

The final decision when selecting the foam extruder is one of the key factors in the success of the project. Stability of the production process at the most optimal production cost can be achieved only if the most important technological processes of polymer extrusion, such as:

Uniform melt homogenization and gas dispersion into the melt; qualitative mixing;

Stability of formation of homogeneous gas structural elements;

Control of polymer expansion and many other technological factors.

All this critically affects the quality of foamed materials, production cost and the final value. FAP is proud that, thanks to its vast knowledge and engineering expertise the counter-rotating twin-screw extrusion technology with developed foam extrusion dies for thin and thick foams has enabled its customers worldwide to produce materials with high physical-mechanical properties, even at ultra-low densities, when the market demands it.

New opportunities

Low processing costs and the use of up to 100% recycled materials in the production are among the most important factors in the use of non-crosslinked physically PE/PP foam in production of noise insulation of interfloor ceilings, of thermal insulation in high ambient temperatures, of thermal insulation for windows aluminum profiles, of foam food trays, of heat and sound insulation for automotive and aviation industries, etc.

In November 2023, IFC, together with a partner, carried out a series of tests to obtain a new product from partially cross-linked physically foamed polyethylene using carbon dioxide (CO2) as a blowing agent. This foam, using a special grafted LDPE with a cross-linked catalyst, allows to use it at temperatures up to 95-100 C° allowing to partially replace traditional chemically cross-linked foamed PE, opening up completely new markets, and making a contribution to “closed loop” economy.

FAP develops by actively analyzing and adapting to changes and developments in the foam markets, supporting the successful diversification of its customers, who not only produce a versatile product, but also discover new perspectives and production opportunities in alternative niches.