Masterbatches for
Foam Extrusion
Industry-grade masterbatches engineered for EPE & XLPE foam processes — delivering consistency, colour brilliance, and superior cellular structure in every run.
What is Foam Extrusion
Creating Structure
From the Inside Out
Foam extrusion is the process of melting plastic in an extruder, then introducing a foaming chemical to create a uniform cellular structure within molten plastic. The foamed material is then formed into sheets, rolls, or custom shapes through extrusion or moulding.
The two most widely used foam extrusion processes are EPE (Expanded Polyethylene) and XLPE (Cross-linked Polyethylene) — each delivering unique performance properties for specific end uses.
Foam Types
EPE & XLPE — Two Pillars
of Foam Technology
Expanded Polyethylene
Made by melting expanded pellets (EPE beads) through heating, subjecting them to a blowing agent, then expanding through cooling into a mould. The result is a lightweight, semi-rigid, flexible closed-cell foam prized for impact absorption, vibration dampening, and surface protection.
Cross-Linked PE
Made in a batch process where PE is mixed with organic peroxide and blowing agent, then compressed and cross-linked through heat and pressure. The resulting closed-cell foam features low moisture permeability and high buoyancy, making it ideal for demanding applications.
Process of Foam Extrusion
Five Stages.
One Perfect Foam.
From raw polymer to finished foam product — every stage is a critical opportunity where masterbatch quality directly impacts the final result.
Polymer Preparation
PE resin + masterbatch blended in precise dosing for uniform colour & additive distribution.
Melt & Extrusion
Material is melted in the extruder barrel, reaching optimal processing temperature.
Foaming Agent
Blowing agent is injected, nucleating millions of uniform micro-cells within the melt.
Cooling & Forming
Rapid controlled cooling locks the cellular structure into the desired shape or sheet.
Quality & Output
Final product meets density, colour, and mechanical specs — ready for end-use.
What You Need
Masterbatches Engineered
for Foam Extrusion
Foam extrusion demands a precise combination of masterbatch types to achieve consistent colour, optimised processing, and superior functional properties throughout the foam structure.
Colour Masterbatches
Specially formulated for uniform dispersion in low-density foam matrices. Heat-stable pigments resist migration and blooming during foam expansion.
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White / TiO₂ Masterbatches
High-opacity white for packaging foam requiring clean aesthetics. TiO₂ loading optimised to avoid interference with cell nucleation.
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UV Stabiliser Masterbatches
Protects foam against UV-induced degradation and colour fading in outdoor applications — critical for construction, agriculture, and geosynthetic uses.
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Flame Retardant Masterbatches
Meets fire safety standards for construction and automotive foam grades. Halogen-free options available for environmental compliance.
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️Antistatic Masterbatches
Prevents static buildup in electronics packaging foam. Critical for EPE used in protection of PCBs, semiconductors, and sensitive equipment.
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️Processing Aid Masterbatches
Reduces die pressure, improves surface finish, and enhances extrusion output rates — enabling smoother production at lower energy costs.
Learn MoreKey Features
Built for the
Demands of Foam
Superior Pigment Dispersion
Nano-milled pigments ensure perfect dispersion even in the highly expanded, low-viscosity melt typical of foam extrusion. No streaks, no agglomerates — just flawless colour across every cell layer.
Thermal Stability
Formulated to withstand the elevated processing temperatures of cross-linking operations without colour shift, degradation, or gas release that could disturb foam cell structure.
Low Dosage Efficiency
High pigment and additive loading in the masterbatch means lower letdown ratios — reducing cost per kg of final foam product significantly.
Foam-Cell Compatibility
Carrier resins carefully matched to the base PE polymer, ensuring zero interference with cell nucleation and foaming kinetics.
Consistent Batch-to-Batch Quality
ISO 9001:2015 certified manufacturing with in-process QC ensures every masterbatch lot meets identical colour and additive specifications — critical for continuous foam production lines.
Custom Colour Matching
In-house colour laboratory matches any Pantone, RAL, or customer-supplied sample with precision Delta-E measurement — including colour standards for foam-expanded states.
Key Benefits
Why Quality
Masterbatch Matters
Precise Colour Control
Achieve consistent colour across long production runs — essential for branded packaging and consumer foam products.
Reduced Production Waste
Consistent dispersion and stable chemistry mean fewer rejected batches, off-spec rolls, and production downtime.
Smooth Processing
Compatible carrier resins and optimised flow properties prevent die buildup, surging, and pressure spikes during extrusion.
Structural Integrity
Additives like antioxidants and thermal stabilisers protect foam integrity during processing and the product's service life.
Lower Total Cost
Higher loading concentrations mean lower masterbatch addition levels — stretching your raw material budget further without compromising quality.
Regulatory Compliance
REACH-compliant and RoHS-friendly formulations available for export and food-contact foam packaging applications.
End Products
Where Foam Extrusion
Meets Real Life
From protective packaging to life-saving flotation devices — foam extrusion products are everywhere. Bajaj masterbatches colour and protect every one of them.
Protective Packaging
EPE foam sheets and rolls for fragile goods, electronics, and e-commerce shipments
Gym & Yoga Mats
EPE foam mats for fitness, yoga, and recreational activities requiring cushioning
Construction Boards
XLPE thermal & acoustic insulation panels for walls, floors, and roofing
Flotation Devices
XLPE buoyancy blocks for life jackets, pool floats, and marine equipment
Industrial Flooring
Anti-fatigue and anti-slip foam tiles for factory floors and work stations
Gaskets & Seals
Precision-cut XLPE foam seals for automotive, HVAC, and industrial equipment
Automotive Padding
Interior trim, door padding, and under-carpet acoustic insulation in vehicles
Food Processing
Hygienic XLPE foam trays and gaskets meeting food safety standards
Grades We Offer
Specialised Masterbatch
Grades for Foam Extrusion
| Masterbatch Type | Base Polymer | Process | Key Function |
|---|---|---|---|
| Colour Masterbatch – Foam Grade | LDPE / EVA | EPE | Uniform colour dispersion in expanded foam |
| White / TiO₂ Masterbatch | LDPE | EPE XLPE | High opacity & whiteness in foam sheets |
| UV Stabiliser Masterbatch | PE | XLPE | Outdoor UV resistance & colour retention |
| Flame Retardant Masterbatch | PE | XLPE | Fire safety compliance for construction use |
| Antistatic Masterbatch | LDPE | EPE | Static dissipation for electronics packaging |
| Antioxidant Masterbatch | PE | EPE XLPE | Thermal stability & long-term durability |
| Processing Aid Masterbatch | PE | Both | Reduced die pressure & improved surface finish |
Why Choose Bajaj Masterbatches?
For over 30 years, Bajaj has been India's trusted partner for polymer solutions — combining world-class R&D with manufacturing excellence and a relentless commitment to quality.
In-House R&D Lab
Dedicated research and development team continuously refining formulations for foam-specific applications — addressing unique challenges like blowing agent compatibility and low-density dispersion.
ISO 9001:2015 Certified
TUV Nord certified quality management system ensures every batch of masterbatch meets stringent specifications — from raw material intake to final dispatch.
Precision Colour Lab
State-of-the-art colour matching laboratory with spectrophotometric measurement — capable of replicating any colour standard in foam-expanded state with accurate ΔE values.
PAN India Presence
Manufacturing and distribution network spanning Navi Mumbai, Gwalior, and Chennai — with dedicated regional contacts for North, South, Central & Export enquiries.
Technical Support
Application engineers available to support process optimisation, troubleshoot dispersion issues, and recommend the right grade for your specific foam extrusion setup.
Custom Formulations
Bespoke masterbatch development for unique foam grades — whether you need a specific regulatory compliance, end-use performance target, or colour standard.
Bajaj Masterbatches
Ready to Elevate Your
Foam Production?
Connect with our foam extrusion specialists and get a custom masterbatch recommendation tailored to your process and end-product requirements.
📧 emarket@bajajin.com
