Promix Trials Automotive Packaging Microcell Technology at Scale

Promix Solutions is conducting industrial-scale trials of its Microcell Technology in automotive packaging to evaluate waste reduction, recyclability, and cost impacts for manufacturers and logistics providers. Announced in late 2025, the project aims to reduce raw material usage by up to 50%, maintain mechanical performance, and ensure compatibility with current recycling processes. Trials are underway at several European automotive packaging production sites.

Background

Promix Microcell Technology employs gases such as CO₂ and N₂ to generate a microcellular foam structure within polymers, decreasing product weight by 20-50% and reducing both material and CO₂ emissions in extrusion operations offline sources report weight reductions of 20-50% via microcellular foaming-variations span 20-50%, depending on the polymer and process^{1Promix Solutions auf der K Messe: Die Extrusion der Zukunft − Signifikante Materialeinsparungen und smarte Prozesskontrolle}. Over 300 systems have been installed globally by Promix and industry partners, either as retrofits or new units in packaging, automotive, and other sectors^{2Trade show highlight: Microcell Technology - saves raw material costs and protects the environment}. The technology retains mechanical strength and recyclability; trials show PET trays produced with microcell foaming match the top-load performance of unfoamed trays while remaining lighter and fully recyclable^{3Promix Solutions: Schaumextrusion mit weniger Material | K-AKTUELL}.

Details

Initial data indicates material use reductions of 20-30% in automotive packaging components such as trays and films. For an extrusion line processing 500 kg of plastic per hour, daily raw material savings can reach 3.6 tonnes, delivering notable cost advantages-estimated at thousands of euros per day per line Promix has reported daily savings of up to 3.6 tonnes of plastic-or roughly €3,600 daily-per 500 kg/h extrusion line^{4Weniger ist mehr - Gewichtseinsparung bei Kunststoffverpackungen -- interpack 2026 - Verpackung Messe}. Financial models from pilot partners suggest payback periods under 12 months, consistent with Promix system claims^{5Foam Extrusion System | Microcellular CO₂/N₂ Foaming | Promix Technology}.

Mechanical properties under load and handling stress are maintained at levels comparable to traditional packaging. The microcellular structure enhances shock absorption and reduces density, supporting weight reduction and maintaining functional performance-a significant benefit in supply chain logistics^{6The future of extrusion - significant material savings and smart process control - News at Plastech Vortal}. Recyclability is not compromised, as CO₂/N₂ agents used in foaming do not accumulate or affect recyclate quality^{3Promix Solutions: Schaumextrusion mit weniger Material | K-AKTUELL}.

Outlook

Trials are set to conclude by mid-2026, with final assessments of cost, performance, and recyclability metrics to follow. Pending positive outcomes, Promix plans broader deployment in automotive packaging, anticipating alignment with EU Packaging and Packaging Waste Regulation (PPWR) requirements for full recyclability and increased recycled content by 2030^{7Recyclable Packaging Designed to Meet PPWR Demands - Borealis}.

Automotive packaging engineers, procurement leads, and logistics managers are advised to monitor these developments, as early results indicate microcell technology could provide a scalable solution to lower material costs, reduce carbon emissions, and comply with evolving regulatory standards, without sacrificing functional integrity.