Polypropylene foam uses in the HVAC industry

Polypropylene foam presents extraordinary possibilities for the HVAC industry and can be integrated across a diverse range of elements within this sector. As a consequence, finding a trustworthy expanded polypropylene foam supplier might be key to maintaining quality in energy performance and cost-effectiveness in HVAC systems.

Keep reading to learn about the benefits of expanded polypropylene foam and how it’s currently being incorporated into HVAC components.

Expanded polypropylene foam: what it is


Expanded Polypropylene (EPP) is a trustworthy, versatile and tested material used across a wide range of industries. 

Made of polypropylene resin, along with a combination of other components, Beads are expanded under controlled conditions in a complex process that requires technical expertise and the right technologies. these beads are then injected into molds in order to generate the desired shape in a cost-effective process that’s easily replicated. 

This material is known for some of its extraordinary features, which include: 

  • Energy absorption
  • Thermal insulation
  • Impact resistance
  • Chemical resistance
  • Water resistance
  • High strength to weight ratio
  • 100% recyclable and a low carbon footprint

Because of this material’s possibilities, it’s increasingly demanded as its prospective market growth reveals: it’s expected to grow at a compound annual growth rate (CAGR) of 6.3% from 2021 to 2028.

Why Polypropylene foam is a perfect material for HVAC Components?

Applying EPP pieces to HVAC components means an increase in these systems’ efficiency, and energy- savings. There are at least 4 reasons for this:

1. Polypropylene foam versatility, customization and easy installation

Polypropylene foam can present a wide range of densities, from 15 to 250 g/l, which can adjust to each project’s needs and generate customized components

It’s also easily molded into the desired shape, as well as presenting an easy encasing for HVAC components.

At the same time, it can be manipulated in a simple way, which also facilitates its incorporation into HVAC installations: it can be cut using hand tools, and integrated in ducts, fittings, and other HVAC components.

2. Expanded polypropylene sustainability

Incorporated into HVAC systems, expanded polypropylene foam helps enhance their energy consumption. Its recyclability is an additional sustainable benefit, as well as its. lightweights, which translates into fewer transportation costs and a reduced carbon footprint across its whole life cycle.

3. EPP: the strongest and most lightweight expanded foam

Polypropylene foam presents a high strength to weight ratio. On the one hand, it presents outstanding energy-absorbing properties and load-bearing qualities, while being very durable in terms of its lifecycle. At the same time, this is an ultra-light material.

This translates into unique benefits for HVAC systems. For instance, it allows for the construction of wall-mounted systems in some air conditioning and ventilation models,  and it makes suspension systems unnecessary.

4. Insulation

EPP foam provides excellent thermal insulation, an extra advantage to improve energy efficiency in HVAC systems and reduce heat loss. This material is also outstanding in providing acoustic insulation so that it minimizes noisy HVAC systems.


You might also be interested in: Plastic injection molding trends for 2022 

Different uses of expanded polypropylene foam in the HVAC Sector

Ducts and fittings

This material’s low thermal conductivity (usually at a level of level of λ = 0.036-0,040 [W/m*k]) makes polypropylene foam ideal for duct and pipe manufacturing in such a thermal-dependent industry as the HVAC sector. This means it eliminates thermal bridges and can be designed to fit a specific tightness class. 

For instance, channels developed with our customers and manufactured by Knauf Appliances are made in various diameters and lengths, as well as different wall thicknesses in order to fit each project’s requirements. 

At the same time, these systems present a great ergonomy, so that their assembly, transport, and installation are simple and quick: they can be cut using hand tools, additional screws or fasteners are usually not required and suspension systems are virtually unnecessary. 

Heat recovery systems

Heat recovery systems are essential units in the HVAC industry today, in search of optimizing energy use and expanding their technical possibilities. In such a quest, these systems’ goal is mainly to use a mechanical ventilation system to help reuse up to 90% of the energy located within a room.

Because of its high thermal resistance and its versatility and flexibility, expanded polypropylene foam has become a highly valued material to fabricate heat recovery systems. 

At the same time, the material can be used both to manufacture new heat recovery systems and replace old metallic components with new EPP technical parts that enhance the system’s performance.

In fact, this material can meet air-tightness requirements in HVAC systems. For instance, at Knauf Appliances we’ve committed to a level of 2%  air leakage, which goes beyond most accepted levels across national and international standards, knowing this makes a difference for our HVAC industry partners.

You might also be interested in: HVAC Market Trends Expected to Heat Up in 2022



Polypropylene foam provides optimal insulation for pumps, water heaters, and hydraulic systems, as it remains stable over a wide temperature range.

All in all, accessing all these benefits depends on finding the right expanded polypropylene foam supplier which is reliable and can provide experience in the field while, at the same time, guaranteeing a constant connection to the industries’ needs and development.

At Knauf Appliances we’ve got decades-long experience in manufacturing expanded polypropylene foam technical parts and have also specialized in generating custom solutions for the HVAC system.

Want to learn more about the possibilities of polypropylene foam for the HVAC industry? Download our free ebook Technical manual about expanded foam in the industry’ and learn more about this material’s possibilities and advantages.

* The image used in this post belongs to ALNOR Systemy Wentylacji who has in exclusive the rights to its use and reproduction.

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