Three-stage process

Our core foaming technology remains a key differentiator and is highly applicable across the industries we serve, where our scale and automation offer efficiencies and consistency at industrial volumes.

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 unrivalled uniform, pure, low toxicity and durable materials with excellent fire resistance, high-temperature stability, toughness and insulation.

Polymers and granules

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.

Semi-solid structure

Stage 2

Nitrogen saturation
Slabs are loaded into a high-pressure autoclave. Operating at temperatures up to 250°C, 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 unexpanded slabs before they are unloaded.

Foam sheets

Stage 3

Expansion
The nitrogen-charged slabs are loaded into a large lower-pressure autoclave and, under moderate pressure, are heated to above their melting point. When the pressure is reduced, the nitrogen expands, turning the slab into larger foam sheets. This expansion process is unconstrained and so uniform in each dimension.

View the process

More about three-stage manufacturing

Watch the video to view each step of our unique three stage process. The combination of temperature, pressure and nitrogen borrowed from the atmosphere ensures that our products are durable with excellent fire resistance, and high temperature stability among other key properties.

Zotefoams videos

Watch our videos about our manufacturing processes and the opening of our plant in Poland.

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Zotefoams Webinars

Zotefoams leaders and key industry players discuss industry issues, plus our plans and updates.

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Our brands

AZOTE®

Closed cell, crosslinked polyolefin high-quality foams made from different base polymers.

Evazote®

Closed cell crosslinked ethylene copolymer foam available in a range of densities, colours and grades.

Plastazote®

Closed cell crosslinked polyethylene foam available in different polymer combinations, densities and colours.

Supazote®

Closed cell crosslinked ethylene copolymer foam available in different polymer combinations, densities and colours.

ZOTEK®

The world’s lightest closed cell crosslinked high-performance foams with outstanding Fire, Smoke and Toxicity (FST) properties. 

ZOTEK® F

Inherently flame retardant high-performance closed cell crosslinked fluoropolymer foam with high dielectric strength.

ZOTEK® F OSU

Lighter, cleaner more efficient foams offering unique advantages for aviation and aerospace interiors.

ZOTEK® T

Tough, flexible with supreme cushioning that is ideal for high-impact military protection apparel and high-performance sports.

Ecozote®

LDPE foams with 30% recycled content. Closed cell crosslinked and low-density, the foams have product sustainability at their core.

T-FIT®

Unique insulation technology for cleanrooms, aseptic areas and high-temperature processing environments.

Our three-stage manufacturing process