How Do We Make PermaStripe So Thick?
We produce the thickest and toughest floor marking tape in the world. That is a simple fact. But how do we actually do it?
PermaStripe is not just another floor marking tape. It is fundamentally different in both its construction and its manufacturing process, and that difference starts long before a roll ever reaches a customer. Unlike most tape manufacturers, we are unique in that we produce the heavy‑duty line marking tape that we sell. This vertical integration is rare in our industry, and it exists primarily because of the scale of investment required. A thick plastic extrusion line is a major commitment in terms of capital, expertise, and ongoing development – one that very few companies are prepared to make.
Our PermaStripe production line is entirely separate from our main factory and is located in the beautiful tourist region of Devon, in the southwest of England. While the setting may be scenic, the technology inside is anything but quaint. I recently visited the PermaStripe extrusion line to discuss adding further capabilities that would allow faster production with less downtime. As always, I was struck by just how automated and precise the entire process is. That visit also highlighted something important: we talk a lot about how good PermaStripe is, but not nearly enough about how it is made.
Why PermaStripe Can’t Be Made Like Normal Tape
PermaStripe is simply too thick to be produced like a conventional adhesive tape. Standard tapes are made in wide sheets and then slit down into rolls. Our product doesn’t work that way. Each roll of PermaStripe is produced individually, with the tape being extruded directly into its final form.
At first glance, that sounds like a slow process – and compared to traditional wide‑width tape production, it certainly is. However, what makes the difference is automation. Our PermaStripe line is fully machine‑controlled from start to finish. In fact, we only need one person to operate the entire line, including packing the finished product. Every stage of production is computer‑controlled and precisely monitored, ensuring consistency, accuracy, and repeatability on every single roll.
Extrusion at an Unusual Thickness
Like almost all plastic films, PermaStripe floor marking tape is produced using an extruder. This is where the process becomes highly unusual. The base film of PermaStripe is a full 1mm of solid, homogeneous plastic. In the world of plastic films, that thickness is extraordinary.
We begin with virgin plastic compound, often referred to as “chips” due to their small size. In most cases, we use pre‑pigmented compounds to achieve consistent colour throughout the material. For low‑volume colour runs, we use natural compounds and blend them with masterbatch pigments to achieve the required shade without compromising performance.
The compound is heated to around 160°C and subjected to extreme pressure – hundreds of bar – using a specially designed, shaped screw inside the extruder. This transforms the solid chips into a molten plastic under tightly controlled conditions. That molten material is then forced through an extrusion shaping tool.
Precision Tooling Makes the Difference
The extrusion tool is a substantial piece of engineering. It is made from solid steel, toughened and chrome‑plated to withstand extreme heat, pressure, and abrasion over long production runs. Internally, the tool is machined to create the precise profile of PermaStripe, with tolerances measured in fractions of a millimetre.
These tools are not simple to design or manufacture. Each one can take months to perfect, and because we produce PermaStripe in large volumes, we always keep at least one spare tool for each size -sometimes two – ready to be installed immediately if required. This level of preparation ensures continuity of supply and consistent quality for our customers.
It is this relentless focus on tooling, process control, and material quality that allows Heskins to produce floor marking material specified by more users around the world than any other comparable product.
Built to Perform, Made to Last
PermaStripe’s thickness is not a marketing gimmick – it is the direct result of engineering choices, investment, and experience. By extruding each roll individually, controlling every parameter, and using robust tooling designed for extreme conditions, we create a floor marking tape that is tougher, thicker, and more durable than anything else on the market.
That is how we make PermaStripe so thick. Not by cutting corners, but by building the capability to do things properly – and doing them better than anyone else.