The Zotefoams difference

Zotefoams manufactures a wide range of lightweight, crosslinked block foams using variations of our unique nitrogen expansion manufacturing process. This affords an exclusive combination of beneficial characteristics – uniformity, purity, low toxicity and durability – that differentiates Zotefoams’ materials from all other foams.

The unique, uniform cell structure of Zotefoams materials makes our products a critical component in a world of everyday applications.

View the video to see how Zotefoams materials are made >>

A unique manufacturing process

Zotefoams produces high-performance, closed cell, crosslinked foams from common and engineering polymers using temperature, pressure and nitrogen borrowed from the atmosphere. The combination of foaming process and polymer performance delivers properties such as excellent fire resistance, high-temperature stability, toughness and insulation, which are prized in a wide range of demanding applications.

Stage 1

Extrusion and crosslinking

Polymer and any additives (colours, fire retardants, conductive agents) are extruded into a continuous solid plate. The plate passes through an oven, which activates the crosslinking process. The plate then cools and is cut into slabs.

Stage 2

Nitrogen saturation

Slabs are loaded into a high-pressure autoclave. The material is heated above its melting point and pressurised with pure nitrogen gas. Over a long period of time the nitrogen gas diffuses into the slabs. A rapid depressurisation destabilises the absorbed nitrogen, nucleating cells in the slab. The slabs are then cooled under pressure in the autoclave, locking the nitrogen in the un-expanded slabs, prior to them being unloaded. Operating temperatures reach up to 250ºC / 482ºF and pressures 675 bar / 10,000 psi.

Stage 3

Extrusion and crosslinking

The nitrogen-charged slabs are loaded into a large lower-pressure autoclave and, under moderate pressure, are heated above their melting point. When the pressure is reduced the nitrogen expands, turning the slab into a larger foam sheet. This expansion process is unconstrained and so uniform in each dimension. Operating temperatures reach up to 250ºC / 482ºF and pressures 17 bar / 250psi.

MuCell^®

Microcellular Extrusion Technology

MuCell® microcellular extrusion technology uses microcellular bubbles to produce a foamed core wrapped in a solid skin. This process delivers one integral material that looks and performs like a solid version, but typically uses 10-15% less plastic. Using less polymer is not only environmentally beneficial and sustainable but also produces cost and weight saving too.