In the U.S., most sheet extrusion lines utilize single screw extruders due to cost considerations. However, to enhance product development flexibility, FPP employs twin screw extruders for both the skin and core layers.

Certain heat-sensitive materials, such as PET, and specific additives require a single heating cycle to maintain their desired properties and performance. When using single screw extruders, only virgin resins can be processed for these materials, as pre-compounded materials may degrade, losing attributes like strength and clarity during extrusion. To maximize material performance, avoiding a second heat cycle is generally preferred.

 FPP's twin screw extruders can efficiently homogenizes up to six ingredients and extrudes them onto the sheet line chiller roll within minutes. This capability allows heat-sensitive materials to incorporate additives as specified by customers, achieving unique properties that single screw extrusion lines cannot provide due to their inability to modify formulations

With Over 20 years of expertise in polymer formulation development, FPP has received positive feedback from government agencies, including the Navy, Army, and ARL. The company is equipped with a comprehensive range of feeders and feeder screws to handle various additives, including pellets, powder, fiber, granules, flakes, and cohesive materials. These include single screw feeders, twin screw feeders, and vibratory feeders with specialized screw designs. The feeders operate at rates from 0.1 lbs/hr to 1000 lbs/hr, meeting diverse formulations requirements.

To support production demands, FPP utilizes two high-capacity 6000-lb drying hoppers capable of drying engineering resins such as PET, nylon, PC, and PEI before seamlessly conveying them to the twin screw extruder for processing