Agripak developed dedicated know how and technology for the etxrusion and thermoforming of foam PP (EPP) for th eproduction of food packages. Agripak can implement this technology into new machines supplied by Agripak or in existing ones.

1. Flat Die Extrusion of EPP Sheet for
Thermoforming of Food Containers
Fabio Terragni
Agripak srl - Italy
Plastic Processing Machinery

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Definitions
 Material : EPP - expanded PP
chemically foamed PP
medium density foam (500 - 700 kg/m3)
 Product : sheet for thermoforming
flat die conventional technology
thickness range 0.8 - 3 mm
 Market : packaging
thermoformed items for food packaging
dairy, hot food, ice cream, microwave, MAP

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Why EPP ?
 Environmentally correct material
EPP item is up to 40 % lighter than corresponding PP product
 Typical foam inherited properties
mechanical / insulation / ease of thermoforming
 Cost
EPP product is cheaper than corresponding PP product
COMPETITION WITH EXISTING RIGID PLASTIC CONTAINER IN PP/PS
NEW DEVELOPMENTS FOR SPECIALTY APPLICATIONS
EPP POTENTIAL MARKET :

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How does EPP work ?
 New PP grades available
High Melt Strength PP, Mixture of PPs
 New chemical foaming agents available
Endothermic blowing agents (CO2)
 New extrusion machinery available
EXP flat-die extrusion line
THE EPP EXTRUSION PROJECT
A JOINT MULTINATIONAL APPLIED R&D PROJECT
4 Companies, 16 months development, 1.2 million USD investment

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EPP raw materials
 New PP resins
 Endothermic blowing agents
 Formulation basics
New PP grades from different suppliers and dedicated blowing agents
has increased formulation alternatives and reduced cost of mix
PRESENT SCENARIO…..

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EPP extrusion technology
 Flat die extrusion
well known technology
easy process
 Chemical foaming
as easy as adding a common additive or master
no expensive ancillaries required
 General purpose line
process EPP as well as PP, PS, PET

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Compact EXP extrusion line
 Dosing
Accurate CBA dosing
 Extruders
specific screw design
 Mixer
homogeneous mixing
 Feedblock
coextrusion for lower density
 Flat die
special land design
special lips thermal control

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Compact EXP performance
 Density
EPP 560 kg/m3
PP 920 kg/m3
 EPS 780 kg/m3
PS 1050 kg/m3

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EPP processing
 Feeding, dosing and mixing
 Extrusion parameters
 Process set-up and control
 Quality control
Scraps recycling. IN-LINE thermoforming. Coextrusion even with
barrier resins. Special formulations.
OTHER ISSUES……

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EPP economics
 Raw material formulation
 Machinery
 Operation
 Finished product
 Green tax advantages
 Premium price novelty

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EPP thermoforming
 Machinery
Form Cut Stack or Form and cut in place
Air pressure forming vacuum assisted
 Performance
better behavior than PP
reduced cycle time close to PS
 Final products considerations
different design for new performances

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EPP thermoforming
 Some Products

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FOR MORE INFORMATION……
 EPP is ready to enter
the packaging market
 Most converters are
ready to implement EPP
in their factories
 Flat die extrusion is a
viable way to EPP
www.agripak.com