Manufacturer of lightweight XPS panels (AIRPLAC, AERFLY) – from extrusion to recycling, manufactured entirely in Europe

AERPANEL

St-Georges de Reneins (FR) · Neunkirchen (DE) · Leigh on Sea, Essex (GB)New on Amplifa

1992Founded (production start in France)

1.500.000 m²/JahrPanels produced

100%Internalized production processes

400References in stock

20European countries supplied

About AERPANEL

AERPANEL is a family-run, independent industrial company that manufactures lightweight panels based on extruded polystyrene (XPS). The product range includes, under the AIRPLAC (paper-foam board panels) and AERFLY (rigid panels) brands, materials for the graphic arts industry (3D model making, framing, creative design), visual communication (large-format printing, merchandising, outdoor advertising) and interior fitting (trains, leisure vehicles, bathrooms, offices). The entire value chain – from raw material to finished product – is internalized: AERPANEL extrudes XPS foams, coats using hotmelt, laminates, and develops and builds its own production machines. An integrated recycling service enables closed-loop operation in which the recycled volume equals the production volume. Production takes place in France (since 1992), Germany (Isopor GmbH, since 2000) and the United Kingdom (EMBALL'ISO-M2 ltd, since 2004); the French site has been powered by geothermal energy since 2009. Annual capacity is 1.5 million m² of panels, supplying customers in 20 European countries.

Site: St-Georges de Reneins
Processes: Extrusion of XPS foams, Recycling of XPS foams / polystyrene, Enduction hotmelt, Lamination, Manufacture of lightweight panels (paper-foam board AIRPLAC, rigid panels AERFLY), Direct printing on panels / large-format printing, Recycling service (circular economy), XPS foam extrusion
Materials: XPS foam (extruded polystyrene – AIRPLAC, AERFLY, VISUAL), Polystyrene, Paper-foam board (composite panels), Extruded polystyrene (AIRPLAC, AERFLY, VISUAL), Paper-foam board panels (composite)
Certificates: Integrated R&D and in-house machine manufacturing, 100% recyclable products, Geothermal/decarbonized site
Founded: 1992
Industries: Graphic Arts (model making, framing, craft supplies), Visual Communication (large-format printing, merchandising, outdoor advertising), Interior Fitting (trains, leisure vehicles, bathrooms, offices), Graphic Arts (model making, framing, craft supplies), Fitting/Interior Fitting (trains, leisure vehicles, bathrooms, offices)

01
Extrusion of XPS foam
02
Enduction (hotmelt coating)
03
Lamination/face bonding
04
Cutting/processing
05
Printing finishing (large format)
06
Recycling and return to the cycle

Materials & Processes

XPS

Extruded polystyrene (AIRPLAC, AERFLY, VISUAL)

Lightweight, rigid foam core for panels with high bending stiffness at low weight, 100% recyclable.

Polystyrene

Base material of the extrusion; at the German site, returned quantities are recycled in production strength.

Paper-foam board panels (composite)

XPS core with paper/cardboard facings, easy to cut and print for graphic arts and model-making applications.

Sites

St-Georges de Reneins

Production/Distribution, headquarters

Materials: XPS foam, polystyrene, paper-foam board

XPS extrusion
Hotmelt enduction
Lamination lines
Recycling facilities
Geothermal energy supply

Neunkirchen

Production (Isopor GmbH)

Materials: Polystyrene recycling, XPS foam

Recycling facilities (recycled volume ≈ production volume)

Leigh on Sea – Essex

Distribution/Site (EMBALL'ISO-M2 ltd)

Products & Components

**AIRPLAC core**Extrusion/Lamination · Graphic Arts

**AIRPLAC Black Texture**Lamination · Visual Communication

**AERFLY panels (fit-out)**XPS extrusion · Interior Fitting

**AIRPLAC CORE laser cutting**Laser cutting · Graphic Arts

Inside the production

AIRPLAC CORE test on a laser cutting machine from FLUX Europe

Industries

Graphic Arts (model making, framing, craft supplies)Visual Communication (large-format printing, merchandising, outdoor advertising)Interior Fitting (trains, leisure vehicles, bathrooms, offices)Graphic Arts (model making, framing, craft supplies)Fitting/Interior Fitting (trains, leisure vehicles, bathrooms, offices)

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
Extrusion of XPS foamsPlastics	–	–	–	–	XPS foam, Polystyrene
Recycling of XPS foams / polystyrenePlastics	–	–	–	–	Polystyrene, XPS foam
Enduction hotmeltJoining	–	–	–	–	XPS foam (Airplac, Aerfly)
LaminationPlastics	–	–	–	–	XPS foam (Airplac, Aerfly), Cardboard (facings)
Manufacture of lightweight panels (paper-foam board AIRPLAC, rigid panels AERFLY)Plastics	–	–	–	–	XPS foam, Paper-foam board, Composite panels
Direct printing on panels / large-format printingSurface treatment	–	–	–	–	AERFLY, VISUAL, AIRPLAC

1 Anlagen & Maschinen

Machine	Manufacturer / model	Quantity	Working area	Year built	Site
Own production machines (XPS foam extrusion, recycling, hotmelt enduction, lamination)	AERPANEL	–	–	–	France (St-Georges de Reneins), Germany (Neunkirchen, Isopor GmbH), UK (Leigh

Additional services

Recycling service (circular economy)XPS foam extrusionRecyclingHotmelt laminationLaminationIn-house development/manufacture of production machinesIntegrated R&D

Reference customers

CMH ParisFLUX EuropeSEPR (École des imprimeurs de Lyon)

Quality & Environment

All industrial processes – extrusion, enduction, lamination and recycling – are internalized, which enables complete control of manufacturing quality. The German plant recycles polystyrene in a volume that matches the production volume; the French site is decarbonized through geothermal energy and French electricity.

Evidence	St-Georges de Reneins	Neunkirchen	Leigh on Sea – Essex
Integrated R&D and in-house machine manufacturing
100% recyclable products
Geothermal/decarbonized site

History

1992
Production start in France
2000
Production start in Germany (Isopor GmbH, Neunkirchen)
2004
Production/Site start in England (EMBALL'ISO-M2 ltd)
2009
Establishment of the pioneering site in France with geothermal energy