Inside the plant
Sheet cannot be printed before it is surface treated, and it cannot be treated before it leaves the die. The sequence is the process.
One site, from resin to finished part.
Extrusion, treatment, cutting, printing and conversion happen under one roof — which is what lets us hold a specification from the raw pellet through to the box that leaves the door. Our in-house recycling programme closes the loop by taking used sheet back and reprocessing it.
Seven stages, in the only order they work.
Resin & masterbatch
Polypropylene co-polymer and homo-polymer resin is blended with masterbatch to the specified colour and additive package. This is where UV protectant, fire retardant and anti-static properties enter the material — they are compounded in, not applied afterwards, which is why they survive the life of the sheet.
Twin-wall extrusion
The melt is forced through a die that forms both flat walls and the vertical ribs between them as one continuous profile. Because the profile runs continuously, length is set by the order rather than by a standard sheet size.
Calibration & cooling
The profile is held to gauge as it cools. Wall thickness and rib pitch are set here, and together they decide the two numbers that matter most to the customer: how stiff the sheet is, and what it weighs per square metre.
Corona treatment
Polypropylene is chemically indifferent to almost everything, which is excellent for chemical resistance and terrible for printing. Both faces are corona treated inline to a maximum of 48 dynes/cm², raising surface energy so inks and adhesives key to the sheet instead of beading off it.
Cutting to size
Sheet is cut to the ordered dimensions. Width is limited to 2400 mm by the die; length is limited only by what you can handle and transport.
Printing & conversion
Screen, flatbed digital, inkjet and flexo printing, then die-cutting, creasing, welding and fitting — turning flat sheet into boxes, dividers, standees, layer pads and guards. This is the stage where a material becomes a product.
Testing & recovery
Material is verified by laboratories — SGS and Modi Laboratory reports are published in full on this site. Used sheet comes back through our in-house recycling programme to be reground and returned to stage one.
Every sheet is specified, not selected.
These are the levers we set per order. Change any one and the sheet behaves differently.
Thickness
Produced between 1.5 and 15 mm. We advise the gauge from the application.
Weight
Expressed in GSM. The higher the GSM, the stronger and stiffer the sheet.
Size
Any requested size. Length as long as required; width limit 2400 mm.
Colour
White, blue, green, black, orange, red, grey and silver. Others matched on request.
Fire retardant
Tell us the fire rating you need to meet and we produce to it.
Custom printing
High-resolution, full-colour printed sheet supplied ready to convert.
Virgin & recycled PP
100% virgin polypropylene, or internally regenerated material.
UV protection
A UV protectant extends sheet and print life in sunlight.
Want to see the test data before you commit?
Both laboratory reports are published in full.