Aurora Plastics Products

PVC Cellular Foam

Auroralite™ compounds are ideal for wood replacement in interior and exterior applications

Aurora Plastics is a dynamic and innovative American company excelling at producing PVC compounds of the highest quality. Our compounds perform consistently and reliably in a variety of applications. Our line of Auroralite™ PVC cellular foam includes powder compounds that generate lightweight, low-density profiles ideal for interior/exterior trim work, windows, garage doors, weather seals, decking, railing, slat wall and much more. Auroralite™ PVC cellular foam extrusion grade compounds can be used as a lightweight wood replacement that can be easily cut, routed and shaped just like real wood, with the added benefit of being rot, warp and crack resistant. Because of its reduced density (lighter weight), processors are able to make more parts with less compound.

Aurora Plastics Adds Value

There is a common misconception that processing cellular PVC is difficult. It is really quite easy, and Aurora Plastics can help. We bring years of experience and technical knowledge to the process and can help you achieve your goals using the best quality compounds. Bring us in to the process early, so we can help you develop a system that perfectly suits your needs.

Extrusion Processes – Free Foam vs. Celuka (‘sell-oo-ka)

There are two methods of producing cellular RPVC parts: “free foaming” and Celuka processing. In the free-foam method, the cellular foam PVC melt expands freely after leaving the die head, prior to entering the calibrator, which is separated from the die. The die opening is smaller than the calibrator opening, allowing for the foam to swell into the calibrator, creating an even foam density distribution across its thickness and resulting in minimal skin formation (see figure 1).

The Celuka process utilizes a mandrel inside the die and typically there is little space between the die and calibrator. The mandrel generates a hollow section as the profile exits the die that encourages the foaming action to fill this hollow by inward foaming. The cooling of the surfaces that come into contact with the calibrator walls creates a very strong, glossy outer skin on the part’s surface while inwardly filling the foam part (see figure 2).

Why Use Auroralite™ Compounds?

Aurora Plastics has decades of experience in RPVC compound manufacturing and processing. We will partner with your company from need recognition and material selection to providing advice on appropriate extrusion processing equipment and conditions in order to meet and exceed your expectations.

Our Auroralite™ compounds are available in a broad range of densities to meet the architectural and structural requirements of the desired application. Auroralite™ compounds possess excellent uniform cell structure which drives better physical properties. We even have hybrid free-foam/Celuka PVC cellular compounds that can be customized to meet your needs. When you put our experience to work for you, the cellular PVC process becomes quick and easy.

Benefits of Cellular PVC

  • Ease of processing
  • Can run on a single- or twin-screw extruder
  • Less dense (lighter) than wood
  • Can be painted or premixed with color
  • Rot-resistant
  • Fire-retardant
  • Pest-resistant
  • Can be capstocked
  • Easy to install
  • Variety of densities available based on structural requirements