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 plus peroxide plus colour additives are extruded into a continuous sheet of solid polymer.
The sheet of solid polymer passes under an oven at elevated temperatures which fully reacts the peroxide and chemically crosslinks the polymer.
The solid polymer sheet is cut into slabs.

Semi-solid structure

Stage 2

Nitrogen saturation
The solid polymer slabs are put into a high-pressure autoclave. Under conditions of elevated temperatures and high-pressure supercritical nitrogen, the nitrogen is absorbed by the solid polymer. (In compliance with clause 4 of Defence Standard 93 101)
The sheet is cooled trapping the nitrogen in the polymer. The slabs are then removed from the autoclave.

Foam sheets

Stage 3

Expansion
The gas saturated slabs are placed into a low-pressure autoclave. A low pressure is applied to prevent gas escape while the slab is heated to soften the polymer. Once the polymer is softened, the autoclave is de-pressurised, and the slab expands into foam.
The foam sheet is removed from the autoclave and allowed to cool. This is the finished product.

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