PBF | Particle Back Foaming
HIGH QUALITY, LIGHTWEIGHT AND SUSTAINABLE.The innovative and sustainable solution for high-quality and affordable lightweight plastic components.
For decades, particle foams - especially polypropylene and polystyrene - have proven their outstanding capabilities as light, insulating, and protective materials. However, we have rethought particle foams and the underlying process. With dynamic cavity heating, we have succeeded in creating backfoamed surfaces directly in the mold. This brings to life molded parts with high-class surfaces at economically attractive conditions.
This technique offers a wide variety of different applications. Precise and dynamic mold temperature control allows us to process additional thermoplastics as particle foams. We can even process thermoplastics made of PET, MPPE, or sea plastics. The ultra-low CO₂ footprint of PS, for example, plus the option to use post-consumer material make this technology a future-proof solution with minimum CO₂ emissions.
This technique offers a wide variety of different applications. Precise and dynamic mold temperature control allows us to process additional thermoplastics as particle foams. We can even process thermoplastics made of PET, MPPE, or sea plastics. The ultra-low CO₂ footprint of PS, for example, plus the option to use post-consumer material make this technology a future-proof solution with minimum CO₂ emissions.
The polystyrene used is supplied in the form of microgranulate and is only expanded immediately before processing. In addition to the low transport volume, the main advantage is that these are thermoplastics that can be part of a functioning circular economy.
In the new process, steam is completely dispensed with, i.e. both the pre-expansion and the processing of the expanded foam beads are fully electric. This reduces energy consumption by around 10 % compared to conventional steaming processes.
Find out more about PBF's innovative technology and development process here.
In the new process, steam is completely dispensed with, i.e. both the pre-expansion and the processing of the expanded foam beads are fully electric. This reduces energy consumption by around 10 % compared to conventional steaming processes.
Find out more about PBF's innovative technology and development process here.
- LOW
WEIGHT - ATTRACTIVE
COMPONENT COSTS - INTEGRATION
OF FUNCTIONS - SUSTAINABLE
MATERIALS
BENEFITS OF PBF TECHNOLOGY
Using as little material as possible saves money and weight. If we succeed in creating all necessary component functions in one single process step, we get components that will occupy a definite place on the market.Installing such components into vehicles helps us save drive energy, not only theoretically but also daily. Weight reserves open the door to even more freedom of design. If the components are recyclable or consist of post-consumer materials, we have made a good decision together.
HOW DOES PARTICLE BACK FOAMING WORK?
Versatile surfaces for interior and exterior applications
Whether smooth, glossy surfaces or textured and matt finishes - PBF technology opens up a wide range of design options for interior and exterior surfaces.
Class-A
Softtouch
Laminating
Partnership from beginning to end
PARAT Technology is the safe choice for your project - we are at your side every step of the way, from the idea to the market launch.Our modern systems and the concentrated expertise of our employees guarantee first-class results at all times.
FULL-SERVICE PARTNER
Extensive Know-How
Modern
Machines
High supply
Reliability
FAQs about PBF
PBF technology is ideal for high‑quality, lightweight and functionally integrated plastic components for both interior and exterior applications in motorhomes and caravans. It is also used wherever low weight, maximum design freedom and high technical performance are required.
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What typical applications exist for PBF technology?
PBF technology is ideal for high‑quality, lightweight and functionally integrated plastic components for both interior and exterior applications in motorhomes and caravans. It is also used wherever low weight, maximum design freedom and high technical performance are required.
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What wall thicknesses, component sizes and shapes are possible with PBF technology?
Because PBF uses dynamically tempered molds, it offers exceptionally high flexibility. Achievable wall thicknesses, sizes and shapes depend on tooling, materials and part design, enabling optimal adaptation to technical requirements.
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What is the maximum component size that can be produced?
The maximum size of a one‑piece component is around 2800 × 1800 mm. Larger components can be produced through intelligent multi‑part construction.
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Can functional integrations and inserts be integrated directly in the process?
Yes. Functional elements or inserts can be fixed directly in the mold and permanently integrated during the foaming process, enabling additional functions without downstream assembly steps.
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How much weight can be saved with PBF components?
The sandwich structure enables weight savings of around 30 to 50% compared to a solid component, depending on the application.
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What insulation properties do PBF components have?
The foam core of the PBF sandwich consists of EPS with a density of around 180 g/dm³, making it an effective insulation material with very good thermal properties.
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How stable are PBF components?
The two thermoformed compact outer skins are spaced apart by a defined EPS foam core, resulting in an extremely stiff and stable sandwich structure.
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Can PBF components be recycled?
Since PBF sandwich components consist entirely of thermoplastics in both the skins and the core, the layers can be mechanically separated and fully recycled at the end of their lifecycle.