Foam Molding Technology
At Knauf Industries we specialize in the production of various foamed plastic components. We use the most proven plastics processing technologies that allow us to apply the recommended solutions widely.
Why choose Knauf Industries as a supplier of expanded plastic components?
Foam plastic molding is a modern technology that we use in a wide range of industrial production projects. With our professional support, companies in various sectors can expect the highest quality of requested plastic parts and production efficiency.
At Knauf Industries Group plants, we specialize in supplying expanded plastic products from materials such as expanded polystyrene (EPS) and expanded polypropylene (EPP).
- We pride ourselves on more than 40 years of experience in delivering innovative solutions to industries such as Home Appliances, HVAC and automotive.
- All of our work is based on the one-stop-shop concept, which involves combining a diverse array of plastic-processing technologies and additional processes. Our customers can expect specialized technological support and efficient process implementation.
- All our solutions are produced with the highest quality standards in view, thanks to which thousands of customers have already trusted us.
- We develop complex solutions for our clients, taking into account their individual needs and requirements. We precede each project with a feasibility study.
- We cooperate with other companies in the plastics processing industry whose factories are located around the world.
- Thanks to the Knauf Group’s strong capital potential, we guarantee smooth implementation of all innovations even in the most demanding expanded plastic molding projects.
What is molding of expanded foamed plastics?
Foam plastic molding is a technique that produces parts by filling a mold with foamed material under high pressure.
The molding process uses pure steam delivered into the mold, allowing the granules of material to permanently bond into the set geometry of the part. Once the part is removed from the mold and cooled, the material takes on its target properties.
One of the most significant advantages of such a technique is the very satisfactory ratio of mechanical strength to low component weight.
Foamed plastic molding at Knauf Industries
Expanded plastics molding technology is increasingly being used to produce components in various industries.
The molding of foamed plastic parts is our major specialty – among the materials we use are expanded polystyrene (EPS) and expanded polypropylene (EPP), as well as plastics, with the trade name Piocelan, which are a combination of the two above-mentioned materials.
The produced technical parts can adopt even the most complex forms, so we can fully customize the design to meet customer requirements.
Examples of foamed plastic molded products for various industries
Foamed plastic molding is one of our most innovative technologies used to produce components for various industries. Among the most relevant advantages of this technique, it is worth mentioning its wide application and the possibility of customizing projects to meet the individual needs of each customer.
Automotive
Home appliances
Industry
Furniture industry
HVAC
Construction industry
Automotive
We produce, among others:
Molded foam components for OEM and TIER 1:
- shock absorbing components
- automotive battery insulation systems
- seat components
- child seat bases.
Example of material used:
One of the materials used in the molding process is EPP, a very unique plastic with a cellular structure, whose greatest advantages are its extreme lightness, strength, shock resistance and flexibility.
Home Appliances white goods and brown goods
We produce, among others:
- reusable packaging
- one-way packaging
- technical parts for equipment insulation
- technical parts like casings and housings
Example of material used:
EPS can be used to make parts and packaging of virtually any shape.
Industry
We produce, among others:
- EPP boards
- insulation boards
- reusable packaging
- corners
- polystyrene fittings
- wedges
Example of material used:
Foamed polystyrene used in the process of plastic molding as much as 98% consists of air enclosed in the granules of the material, which makes it extremely lightweight. In addition, it is odorless and neutral to the environment.
Furniture industry
We produce, among others:
- furniture fillings
- Technical parts
- polystyrene expanded granules.
Foamed plastics are also used as an alternative to traditional plastics, wood or metal for the production of lightweight and durable components.
HVAC
We produce, among others:
- heat pump insulation
- housings for heating boilers
- insulation systems for other HVAC equipment.
Construction industry
We produce, among other things:
- technical parts
- EPS boards for thermal insulation of facades of roofs and floors (white and grey EPS)
- polystyrene boards for foundation protection
- boards for floor heating.
Example of material used:
EPP is a very unique plastic with a porous structure, whose greatest advantages are: lightness, strength, shock resistance and flexibility.
Foam molding - highest quality solutions and services offered at Knauf Industries
A highly qualified staff of engineers and years of experience is a guarantee of professional support. We offer efficient implementation and expert advice at every stage of the project – from the beginning to the final product.
Complex plastic foam molding services
Our support includes different types of projects. We handle both simple operations within foamed plastics processing and the most complex implementations, such as overmolding with metal and plastic inserts:
- We prepare feasibility studies
- We manage the development of tools
- We implement projects for many different industries
- We ensure strict quality control
- We offer products fully in accordance with customers’ requirements
Full engineering and design support
We start each implementation with a comprehensive feasibility study conducted by highly qualified engineers. Our clients can benefit from professional support at every stage of the project.
A wide range of post-production services
In addition to the production process itself, we provide complex support in the implementation of any solution. Our services also include:
- component assembly
- processing of parts
- strict quality control
- packaging
- preparation of parts for shipment.
One-stop-shop. What do we offer?
The extensive experience and numerous realized projects in foam molding as well as injection molding allow us to ensure high quality services. We act as a one-stop-shop for our customers, providing efficient implementation of all processes. We are happy to carry out hybrid projects combining these two technologies – foams and injection, which guarantees a simplified supply process of plastic components for our customers.
- Feasibility Study
- Coordinate the development and production of injection molds
- DFM
- Overmolding and Insert Molding
- Two-component injection molding (2K)
High quality and reliable plastic molding proven by certificates
The quality of our solutions is confirmed by industry certifications such as IATF 16949 and ISO 9001:2009. In addition, with each implementation we take care to reduce the impact of our activities on the environment, as confirmed by the ISO 14001 Certificate.