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With four decades of experience and an extensive library of patents for the extrusion of high-performance foams, Nomaco has deep knowledge of various foam manufacturing technologies. In addition to the many and diverse types of products that we develop for the market at large, Nomaco provides turn-key, custom-developed solutions for clients with complex product and performance requirements.

We use our technical expertise, extensive testing and analytical capabilities, modifiers and converting processes to stretch the performance boundaries of the foam materials we produce.

All of our products are manufactured in the USA. We pride ourselves on delivering high-quality products, supported by excellent customer service, and fast, cost-effective shipping from our facilities in North Carolina and Oklahoma.

Extrusion Manufacturing

foam extrusion manufacturingWe are experts in foam extrusion, including single, crosshead and co-extrusion manufacturing. We continue to be the recognized industry leader in die design and complex profiles. Utilizing advanced 3-D computer modeling and more than 100 years of combined experience in die design, our development engineers have the skill to create solutions for challenging geometries and specifications. Our dies and tooling are fabricated with state-of-the-art machinery capable of holding within 1/10,000 of an inch accuracy, which yields exacting precision during the manufacturing process.

Materials

foam materialsWe manufacture polyethylene, polypropylene, and hybrid foams in rolls, tubes, sheets, planks and unique profiles. Our foams are intrinsically lightweight, durable, recyclable, reusable, and resistant to solvents, chemicals and mold.

For an overview of our materials and their performance properties, download our Materials Selection Guide.

Modifiers

Our engineering and scientific experts can vary formulations to achieve the exact performance an application requires. We can alter cell size, thermal performance, tear strength, softness, flexibility and resiliency. We can even make differing polymers compatible. With a deep understanding of foam properties, we can modify many characteristics of foam to deliver the optimal solution.

A few standard additives that can be integrated into any of our foams include:

  • Antimicrobial
  • Antioxidant
  • Colorants
  • Flame retardant
  • Smoke suppressant
  • UV stabilizer

Sustainable Solutions

If you are seeking a more sustainable material solution, consider our biodegradable or bio-based formulation options.

NomaGreen

NomaGreen™ is our biodegradable polyethylene formulation. It is not starch-based or bio-based, and it will meet all performance requirements for PE foam regardless of moisture, heat, light or mechanical stress. NomaGreen’s biodegradation process only occurs when the foam is placed in a microbe-rich environment, such as a landfill.  Foam made from this formulation can also be reused and recycled in the standard LDPE stream.

NomaGreen passed testing through a third party, independent laboratory to ensure it meets ASTM D-5511 standards for biodegradability. Results showed that after 120 days in the lab, NomaGreen achieved greater than 40% biodegradation.

NomaGreen Natural

NomaGreen™ Natural is a bio-based, closed-cell polyethylene foam made from sugar cane, a renewable resource, yet retains the performance characteristics of standard polyethylene foam. With an indefinite shelf-life, NomaGreen Natural will continue protecting your product for multiple uses, and can easily be recycled in the standard LDPE recycling stream.

Analytical Capabilities

advanced foam technologiesAlong with standard quality controls and measures, Nomaco has a range of in-house analytical capabilities to help ensure our foam products perform to the requirements of the applications in which they will be used. In addition to standard testing, our Research and Development team has the ability to create custom tests when there is no standard. We also work with accredited, independent labs for certification or 3rd party verification. Contact us for more information on our analytical capabilities.

Mechanical Testing

  • Compressive Set
  • Compressive Strength
  • Creep
  • Cushioning properties
  • Density
  • Elongation
  • Flexibility
  • Roller performance
  • Shock absorption
  • Tear
  • Tensile strength

Physical Testing

  • Automated full geometry testing
  • Cell size measurement
  • Dimensional stability
  • Outdoor UV performance

Fire Behavior Testing

  • Flammability
  • Smoke characteristics

Thermal Performance Testing

  • Melt behavior
  • Thermal connectivity
  • Thermal conductivity
  • Thermal resistivity

Material Characterization/Comprehension Testing

  • Capillary rheometry
  • Differential scanning calorimetry (DSC)
  • Fourier transform infrared spectroscopy (FTIR)

Custom Testing

  • Foam breathability
  • Motion transfer in beds
  • Roller performance
  • Other customer specific requirement

Specialized Converting Processes

conversionNomaco simplifies manufacturing processes and reduces labor costs for customers by providing a variety of in-line and offline converting processes.

Specialized Processes:

  • TuffCoating – a patented process that adds a secondary skin to the foam’s outer layer. This skin is flexible, yet durable enough to be used in applications such as playground and ballfield fence padding.
  • Debossing – a process that creates a depression on the exterior surface of the foam. The foam is densified in select areas leaving the desired depression or pattern.
  • Partial cutting – a method used to achieve efficient packaging when making short length parts at high speeds. The result is evenly cut pieces in easy-to-handle segments.

Below is a listing of our standard conversion capabilities. In addition, custom converting processes can be developed.

Standard Converting Processes

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