Technologies & Capabilities

Block Foam Technology


At Zotefoams we focus on producing high-performance, high quality foams, under the brand names AZOTE® and ZOTEK®,  using technologies exclusive to us.

At the heart of what we do is a unique, environmentally friendly process that uses nitrogen gas to produce a range of closed cell cross-linked foams. The process comprises three distinct stages:

  • High quality extrusion and cross-linking of solid polymeric sheet
  • Impregnation of solid sheet with pure nitrogen gas at elevated temperature and extremely high pressure
  • Final expansion of the impregnation solid sheet in the low pressure autoclave

This technology, as well as being environmentally friendly, is extremely flexible. Operating at temperatures up to 250 ºC /  482 ºF allows us to foam a wide range of polymers.  Some of the unique characteristics of Zotefoams products come from the combination of foaming process and polymer performance, giving such attributes as very good fire resistance, high-temperature stability, toughness and insulation.

Regardless of polymer our technology produces foam that is:

  • uniform
  • pure
  • non-toxic
  • lightweight
  • durable

The separation of the process allows very accurate control of the individual parameters governing consistent production of high quality foams.

For more information about our unique process and its advantages read The Zotefoams Difference brochure and have a look at the videos below.

Extrusion Technology

MUCELL® microcellular extrusion technology uses microcellular bubbles to produce a foamed core wrapped in a solid skin as one integral material that looks and performs like a solid version but will typically use 10-15% less plastic. Using less polymer is obviously more environmentally beneficial and sustainable than recycling, but as MUCELL is again based around environmentally friendly nitrogen or carbon dioxide gas the recyclability of the product is completely unaffected.


The standard AZOTE, and ZOTEK ranges of foams are capable of being formulated with properties relevant to specific applications to meet industry standards or unique customer needs. We are continually developing our range of foams to satisfy the expanding needs of our clients, and to this end we offer customer and market specific grades.

We work with our customers offering internal testing and technical support. These facilities are designed to ensure that new applications use the most effective materials, and that existing applications are taking full advantage of the advances in foaming that our R&D departments are focussed on producing.

Internal testing includes such things as

  • mechanical property testing
  • flammability testing
  • temperature aging
  • polymer identification

And our technical support includes

  • advice on suitable materials for new applications
  • provision of test reports to specific standards
  • testing for specific projects
  • advice on replacement products based on datasheets or sample analysis
  • testing of provided samples where data is not available

Internal testing and specific technical support are available on a project-by-project basis following detailed discussion with our commercial staff.