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Union has recently completed the commissioning of a Foam R-PET line in Asia for the extrusion of expanded sheets used in automotive interior composite panels. The project involves the use of two tandem-configured extruders, enabling high production rates with densities ranging from 80 to 220 kg/m3 and thicknesses from 0.8 to 6 mm. Union's tandem solution ensures rapid achievement of extrudate quality, even with a challenging material like PET, where processing temperatures reach up to 320 °C. A rheological study of the product led to the development of a circular die that does not require changing the mandrel, even with varying thicknesses and densities.
A new cooling system for the extruder provides a tolerance of 0.5 °C from the set value - crucial when using gases with limited expansion capability, such as CO2, to ensure ideal cell formation. Equally important is the cooling calibrator, featuring a surface specially designed by Union, which, despite very low friction, provides excellent heat exchange, yielding a high-quality surface finish with impressive appearance and gloss on the extruded material. Expanded PET boasts excellent mechanical strength, high-temperature stability, and is fully recyclable.
