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Zotefoams – market leader in nitrogen expanded PE foam | ISMT
ISMT works with Zotefoams, the market leader in nitrogen expanded PE foam. Read more about production techniques and production lines.
Product line
AZOTE is the overall product line we use at ISMT. This includes several product groups. We use the following:
- Plastazote: This is a closed-cell, crosslinked polyethylene foam that offers strength, heat resistance and formability. Zotefoams produces the lightest crosslinked foams in the world, with densities ranging from 15 kg/m³ to 115 kg/m³. They are used in various industries, including product protection, automotive, aerospace, electronics, healthcare, construction, sports, marine and industrial applications such as seals and gaskets.
- Evazote: This closed-cell, crosslinked ethylene copolymer foam is strong and resilient, available in densities from 30-50 kg/m³. It is used in sectors such as sports, leisure, footwear and construction.
- Ecozote: These are closed-cell, crosslinked foams of low-density polyethylene (LDPE) containing 30% recycled raw materials. Following Ecozote LDR, which contains 30% pre-consumer waste and is already used in many product protection applications, Ecozote PE/R is now being launched. This is the first foam from Zotefoams to contain 30% post-consumer recycled material, certified by EU-Certplast. The material’s fine cell structure and matte black appearance make it perfect for luxury packaging applications.
Zotefoams
Zotefoams is the market leader in nitrogen expanded PE foam. In 2001, our collaboration began with the production of gymnastics mats, which ISMT still makes today. We enjoy working with our partner Zotefoams, partly because of their innovative production of lightweight, crosslinked block foams. These foams are developed via a unique nitrogen expansion process, which links polymers at the molecular level. Thanks to this process, Zotefoams offers materials with unrivalled properties such as uniformity, purity, low toxicity and durability.
Productiontechnology
Zotefoams’ production technology is distinctive and consists of three main stages.
- Extrusion and crosslinking: During the first stage, Polymer and any additives (dyes, flame retardants, conductive agents) are extruded into a continuous solid sheet. The sheet passes through an oven, which activates the crosslinking process. The slab then cools and is cut into sheets.
- Nitrogen saturation: In the second stage, the plates are placed in a special high-pressure autoclave. The material is heated above its melting point and pressurised with pure nitrogen gas. For a long time, the nitrogen gas penetrates the plates. With rapid pressure reduction, cells are formed in the plate.
- Expansion: In the final stage, the nitrogen-filled slabs are loaded into a large low-pressure autoclave and heated under moderate pressure to above their melting point. When the pressure is reduced, the nitrogen expands, turning the slab into a larger foam slab. This expansion process is unlimited and thus uniform in every dimension.
This special process leads to materials with a uniform structure of cells, which offer excellent properties such as fire resistance, stability at high temperatures, strength and insulation. The combination of these techniques allows Zotefoams to provide high-quality, durable and versatile foam products for various applications. Using this technology, ISMT develops unique products for various projects and applications.
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Sustainability
Zotefoams’ products are inherently durable. This is because of their unique technology. Margaret Wegrzyn, business development manager at Zotefoams says: “Because of the unique technology, the products are already naturally sustainable. We use nitrogen for our foams, which is simply in the air around us making chemical additives unnecessary. But the Netherlands, and certainly ISMT, is really leading the way when it comes to sustainability. This matches nicely with our latest addition Ecozote grades which contain 30% recycled material.”
She continues: “Our technology allows us to make our products thinner and therefore lighter without compromising on cushioning. We use less raw materials, so fewer plastics, and if you look further down the chain, less fuel is also needed for transport. Our products are more durable so they are less likely to need replacing. All in all, this has a positive effect on our carbon footprint. This appeals to everyone, but especially a party like ISMT that is so forward-thinking when it comes to sustainability.”
Applications
SMT uses Zoteofams’ products for various applications:
– Industrial packaging
– Sports and leisure articles
– Medical applications
– Construction and infrastructure
– Marine
– Customised products / customer-specific solutions
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