PET Foam Core Production Line
Based on our ECOFEL foam extrusion technology, USEON has developed PET foam board/bead/sheet production lines which can turn waste PET into value-added foam core products for the composite materials.
- Throughput across four models, F100 to F800
- 80–800kg/h
- Foam core density range
- 80–350kg/m³
- Board thickness as extruded
- 5–60mm
- Board width
- 600–1220mm
From waste PET bottles to PET foam core
- 01
The waste
Globally, PET (Polyethylene terephthalate) is one of the highest-volume plastics produced and consumed worldwide, featuring in all aspects of our daily life, especially PET bottles, with millions consumed every day.
- 02
The value
We need solutions for handling such consumer waste product, and USEON Foam Extrusion Technology can turn it into high value-added product PET foam board, which can be used to make composite materials for:
- 03
The green route
Foam extrusion is one of our core competitive advantages, and we are committed to providing green solutions. Our solution uses:
From bottle flake to foam core board
Drying, reactive extrusion and foaming run as one continuous line, followed by the downstream that turns extruded boards into blocks and sheets.
- 01
Drying
Crystallization dryer and dehumidifier. Hot air at a dew point of at least −40 °C for 4 h brings humidity below 50 ppm.
Avoids hydrolysis of the PET melt - 02
Gravimetric dosing
PET and additives are fed at constant rates through gravimetric dosing devices.
- 03Tandem
Reactive extrusion · twin screw
A multifunctional agent increases the molecular weight and introduces long-chain branching, raising the melt foamability of PET.
- 04Tandem
CO₂ blowing agent
CO₂ is injected steadily and dissolves into the PET melt. Dosing system with temperature control.
- 05Tandem
Cooling · single screw & die
The PET/CO₂ solution is cooled and extruded through the foaming die, where cells nucleate and grow.
- 06
Calibrate & plane
Calibrator and surface planer set the board’s thickness and surface.
- 07
Cut-off & edge trim
Boards are conveyed, edge-trimmed and cut to length.
- 08
Laminate & split
Multi-layer lamination machine and splitting machine turn boards into thicker blocks or thinner sheets.
Recycling system
Scraps and chips go back into the production process. Recipe management and remote technical support run through the intelligent control system.
One step
Reaction, mixing and foam extrusion
The line integrates the process of reactive extrusion and foaming, so PET can be foamed straight from flakes.
Raw material
Recycled bottle flakes, or virgin PET
Both virgin and recycled PET can be used as raw material, with a variety of bottle flake sources.
Blowing agent
Eco-friendly CO₂ blowing agent
CO₂ works as the physical blowing agent, dissolved in the PET melt inside the extruder.
The PET foam core you will sell
PET foam is a closed-cell thermoplastic structural foam with certain shear and compression strength, and because of these mechanical properties, it is often used as the core material within a sandwich structure.
- Density
- 80–350kg/m³
- Width
- 600–1220mm
- Thickness
- 5–60mm
- Raw material
- rPET flakes
Higher density, better mechanical properties — and greater weight and cost.
Board width.
Per extruded board. Thicker blocks by multi-layer lamination.
Recycled PET bottle flakes, or virgin PET.
Closed-cell boards straight from the calibrator and surface planer, 5–60 mm thick.
Boards laminated into thicker blocks, then split into sheets to the thickness the composite maker needs.
PET and rPET foam beads.
Superior mechanical properties
Shear and compression strength for sandwich structures; fatigue resistance better than some PVC foam core materials.
High-temperature resistance
Around 150 °C for a short time during processing, around 100 °C long-term in service.
Easy forming
Thermoformable into complex shapes; works with most resins and composite production methods.
Recyclable
Thermoplastic. Scraps return to the line, and waste foam core is easy to recycle.
XPET Foam Machine Models
Four models by throughput, from lab to large scale manufacturing.
Throughput depends on density and board thickness. Tailor-made options available.
A turn-key project, including know-how
- 01
User friendly turn-key project, including know-how transfer
- 02
From lab to large scale manufacturing
- 03
Wide range of product categories
- 04
Tailor-made options available
- 05
Remote technical support through intelligent control system
PET Foam Core Application
PET foam core material is widely used in construction, road transportation, rail transportation, aviation, communication, wind power, and various applications requiring such properties.
Wind Energy
- Wind blade shear webs and shell
- Nacelle covers
- Composite sandwich structural parts
Railway
- Prefabricated rooms for train carriages
- Floor, side wall, roof
- Body and internal structure
Aviation
- Lightweight sandwich panels
- Internal structure
Ocean
- Boat and ship decks
- Internal structure
- Superstructure
Also:Construction · roofs, claddings, domesRoad transportationCommunication
Reference · XPET line
500 kg/h XPET line, tested and running
A tailor-made 500 kg/h PET foam core material production line has been tested successfully. This is a turn-key project, from crystallization dryer and twin screw plus single screw tandem foam extrusion to multi-layer lamination, splitting and recycling.
Beside the complete set of equipment, the package includes knowhow transfer as well. We provide recipe management for different product categories and processing knowhow.
We not only deliver machines, but transfer value.
Start from the bottles
PET bottles are highly recyclable, and our foam lines run on recycled PET flake. We can also supply the PET recycling machines upstream.
PET Recycling solutions
Get a quote
Tell us your board specification, target output and blowing-agent route.
- 01Output check
- 02Layout & utilities
- 03Reference visit
Cliff Zhang
Head of Foam Extrusion Division
Polymer foam extrusion, extrusion machinery R&D and international business development.