Foaming of rigid polyvinyl chloride (PVC) is studied as a function of high molecular weight acrylic processing aids. The industrial process to evaluate quality of foam is discussed in detail. The role of acrylic processing aids to improve melt strength and hence foaming of PVC is explained. It is demonstrated that increase in molecular weight of acrylic processing aids increases its effectiveness. It is found that ultra-high molecular weight processing aids is 25%-30% more efficient than relatively lower, but still high, molecular weight acrylic processing aids. The higher molecular weight processing aids provided comparable foaming performance at lower loading levels. Foaming reduced the density of PVC compounds to 0.32-0.34 g/cm 3 . More than 1000% expansion is achieved in the melt extrusion process using a chemical blowing agent. Fusion characteristics are also studied. Fusion times for initial fusion peaks are in the range of 42-44 s while the fusion times of the second fusion peaks are in the range of 74-94 s. The higher molecular weight processing aids maintained fusion characteristics of PVC compounds, warranting no significant changes in commercial process.