Custom Profile Design & Manufacturing

Custom Profile Design

Our custom capabilities are perfectly matched to the needs of sectors such as composite doors, metal doors, automotive and marine applications.

If we don’t offer a solution for your application then our custom extrusion service will allow you to design, manufacture and test a profile that perfectly matches your requirements, whether it’s part of a new product development program or for a one of specialist project.

We are experts in the extrusion of intumescent seals covering single extrusion, co-extrusion, triplex extrusion, offering an extensive range of ‘Down-line’ specialist production equipment for:

  • Smoke seal insertion
  • Adhesion of thermally fused flippers
  • Self-adhesive tape
  • Printing
  • Specialist Packaging

Pyroplex Intumescent

Our unique intumescent has been specially developed by Pyroplex and exhibits excellent performance characteristics, including:

  • High pressure force during expansion
  • Not affected by humidity or immersion in water
  • Non-toxic and non-fibrous (dust free)
  • Non-flaking and difficult to tear
  • Expansion ratio of 25:1 by volume for perimeter applications
  • Expansion ratio of 10:1 by volume for glazing applications
Custom Intumescent Profiles

Examples of custom profiles

Manufacturing & Testing

Intumescent Testing

When it comes to the design of a custom profile we will also consider the testing the overall system with be subject to and any associated performance characteristics. Our Technical Manager can advise on appropriate test programs for various applications including composite door, metal doors, access hatches and many more.

Our onsite indicative furnace can be used for small scale testing and sample testing prior to full scale testing at UKAS accredited facilities.

Our technical expertise combined with production capability and certification from leading test houses worldwide mean that specifiers and installers have the upmost confidence when selecting Pyroplex solutions.

We have expertise in the testing of to British and European standards and an in depth knowledge of the testing criteria set out in test standards such as:

  • BS 476: Part 22: 1987
  • BS 476: Part 20: 1987
  • BS EN 1634-1: 2008
  • BS EN 1634-3: 2004
  • BS EN 1366-3: 2009
  • BS EN 1366-4: 2006

We also have knowledge of the CE marking process and requirements, having successfully taken our pipe collars, pipe wraps and acrylic through the CE marking process. In addition to the testing requirements we also have a working knowledge of the requirements of leading third party approval schemes such as CERTIFIRE and IFCC Certification.