PROMIX Solutions Advances Intelligent Material and Process Management at Fakuma 2026
At Fakuma 2026, taking place October 12–16 in Friedrichshafen, PROMIX Solutions will present innovative process technologies for mixing, foaming, cooling and process monitoring in plastics processing at Hall A6, Booth 6108. The focus will be on the proven PROMIX Microcell Technology for significantly reducing material consumption, as well as the Visco-P inline viscometer for real-time monitoring and control of extrusion processes. A notable new feature is the availability of the Visco-P with a closed-loop control system and direct connection to metering systems. This allows raw material flows to be automatically controlled based on the viscosity measured in the process. A typical example is the automatic control of the IV value in PET processing.
Up to 50% Material Savings Through Physical Foaming with Microcell Since raw material consumption accounts for the largest share of the CO₂ footprint in extrusion, material efficiency is becoming increasingly important. This is where PROMIX Microcell Technology comes into play: The precise addition of environmentally friendly atmospheric gases creates a fine microcellular foam structure within the polymer. Depending on the application, this can reduce the product weight by 20 to 50%.
In addition to significant material and cost savings, Microcell Technology provides opportunities for product optimization. Depending on the application, properties such as reduced weight, improved thermal and acoustic insulation, enhanced shock absorption, and attractive visual and tactile effects can be achieved. The technology is successfully used in the production of films, sheets, foamcore pipes, profiles and cable jackets, and is suitable for nearly all common polymers. A new field of application is the foaming of monofilaments. Together with an industry partner, PROMIX is currently developing foamed monofilaments for artificial grass applications. Microcell technology, which is available for both new installations and retrofits, has now become widely adopted worldwide. More than 350 industrial Microcell systems are already in successful use, and numerous machine manufacturers integrate the technology into their equipment as standard.
Setting New Standards for PET Foams and Foam Films
The PROCELL foam and nucleating additives have been expanded to include a new grade for PET foams. This is an endothermic blowing agent that does not release water and is therefore perfectly suited for PET. It enables fine cell structures and, at higher dosages, can also be used as a standalone foam additive.
After years of development and optimization, the PROMIX annular die for the efficient production of foam films made from PP and PS is now ready for the market. This innovative technology combines more than 20 years of experience in foam die design and sets new standards in the production of foam films. Thanks to the patented die design, foam density and film thickness tolerances can be further reduced. This leads to substantial material and cost savings as well as higher product quality. The innovative flex-lip design enables precise and reproducible adjustment of film thickness. Even when the die is opened and closed, the set lip geometry is maintained, eliminating time-consuming readjustments and significantly reducing setup times.
Measuring, Monitoring, and Controlling Viscosity in Real Time
The increasing use of recycled materials and raw materials from various sources poses ever-greater challenges for extrusion plants. Fluctuating material qualities make it difficult to maintain consistent product quality and stable processes. With the Visco-P inline viscometer, PROMIX offers a solution for continuously monitoring the melt directly within the production process. The system measures the actual viscosity under real processing conditions directly in the melt stream, without a bypass and without material loss. The maintenance-free measuring module reliably homogenizes the melt and prevents clogging, deposits, or material degradation. This makes the system particularly suitable for recycled materials, filled compounds, and shear-sensitive materials.
At Fakuma, PROMIX will demonstrate the automatic control of the intrinsic viscosity (IV) value during PET extrusion. If the measured IV value falls below the specified setpoint, the system automatically controls the dosing of an IV enhancer until the desired melt quality is restored. The same principle can also be applied, for example, in PP recycling through the metered addition of suitable chain extenders. Additional trend analyses, statistical functions, and reporting features enable comprehensive documentation of process data. User-definable thresholds automatically trigger warning messages in the event of deviations and assist the plant operator in quickly optimizing the process. The Visco-P is compatible with all common extruder types and most thermoplastic materials and can be easily integrated into existing systems. All standard communication interfaces are available for integration into modern production environments and Industry 4.0 concepts.
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