Custom Profile Design & Manufacturing

Custom Profile Design

With an unrivalled reputation for extruding complex components into finished extruded profiles, Pyroplex has custom capabilities ranging from single material extrusions through to technically challenging triple extrusions incorporating multiple cavities and dynamic bubbles with flipper contained in a single extrudate.

The rise in the development of such sealing components has been driven to enhance the performance characteristics of particular systems. Such systems are ultimately achieving higher attestation levels of compliance with other regulatory requirements including fire resistance, limited combustibility, low smoke and toxicity and air and water permeation.

As the demand for complex engineered extrusions increases and the field of application for such products broadens, Pyroplex remains at the forefront of facing future challenges in terms of design and continuous development of its material portfolio and its technical expertise.

Leading European Steel Door Manufacturers have worked with Pyroplex developing complex design geometries for smoke and acoustic performance and also co-extrusion of an integral intumescent material within the same profile.

As with all technically challenging concepts, many extrusions produced today have to serve multiple end use applications, including fire resistance, low smoke and low toxicity, limited ignition and combustibility. Pyroplex has the capabilities to reformulate polymer formulae and develop bespoke compounds to meet the stringent demands across various market sectors.

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


Intumescent Testing

Our Technical Manager can advise on appropriate test programs for various applications including composite doors, metal doors, access hatches and many more.

Our on-site 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 utmost 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 IFC Certification.