How to Reduce Energy Consumption in the Foaming Process? Here's What We Do

In the production of EPE (Expanded Polyethylene) foam, energy consumption — especially during foaming — is a real pain point for factories. Once the foaming machines start running, they can consume electricity rapidly for hours.
So is there a way to maintain product quality while reducing energy use?
The answer is yes。

1.Where Does the High Energy Consumption Come From?

EPE foaming is a typical thermal process, involving high-temperature heating, compression and mixing, foaming agent injection, and rapid cooling. The most energy-consuming steps include:

- Prolonged high-temperature heating
- Motors running at full load continuously
- Inaccurate temperature control causing reheating
- Low air compression efficiency and air leakage

2. What Does the Industry Do? Start Saving Energy from the Source

Across the EPE foaming industry, more equipment manufacturers and factories are adopting the concept of “energy-saving from the source.” Through structural optimization and system-level control, energy efficiency is significantly improved. Here are commonly used strategies in the industry:

✅ Precision Temperature Control
Modern foaming machines typically use multi-zone temperature control (e.g., three-zone heating), paired with PLC logic systems, to maintain ±1°C precision — preventing repeated heating caused by temperature fluctuations.

✅ Variable Frequency Drives + Smart Start-Stop
Unlike traditional motors that run at full power continuously, newer machines use variable frequency drives (VFD) to adjust motor speed based on demand — significantly reducing idle power consumption. Smart start-stop systems further cut standby energy use.

✅ Optimized Screw Design
An optimized screw design enhances material mixing and foaming agent dispersion. This improves foaming quality while reducing heating time — thus saving electricity.

✅ Improved Thermal Insulation
Many machines now include high-density thermal insulation materials around foaming tubes and heating zones, minimizing heat loss and improving overall energy efficiency.

3. Real Case: Customers Are Saving Up to 30% on Energy

One customer using a modern foaming machine reported a 28% reduction in monthly electricity costs with the same daily output. Energy use per ton of foam dropped by nearly 35%.

The EPE foam industry is highly competitive. Saving electricity directly improves your profit margin. Choosing an energy-efficient foaming machine is a win-win — both now and in the long term.