Expanded Polystyrene (EPS)

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WHAT IS EPS?

Expanded Polystyrene (EPS) is a rigid, closed cell, thermoplastic foam material produced from solid beads of polystyrene, which is polymerised from styrene monomer and contains an expansion gas (pentane) dissolved within the polystyrene bead.

Each solid polystyrene bead contains small amounts of gas which expand when heat (in the form of steam) is applied, thus forming closed cells of EPS. These expanded cells occupy approximately 40 times the volume of the original polystyrene bead, and so with a second heat treatment using a mould, large EPS blocks can be moulded into specific customised shapes.

PAGE CONTENTS

1. HISTORY

The commercial development of polystyrene was initially started in Germany by IG Farben in , and built on by US firm Dow Chemical Co. around (1). Though used in both Germany and the US throughout the Second World War, polystyrene foam was more widely introduced by Dow Chemical Co. in under the brand name 'Styrofoam'.  'Styrofoam' - invented by Dow scientist Ray McIntire - was a result of trying to make a new rubber by combining styrene and isobtylene (2), but by doing so he 'accidently' created a foam 30 times lighter and far more flexible than polystyrene (3). 

EPS Properties

Waterproof Insoluble Non-hygroscopic High impact Long-term stable thermal conductivity Non-toxic Chemically inert

2. PROPERTIES

EPS can be moulded in a range of densities from as low as 12kg/m3 up to 50kg/m3 with the resulting properties, such as compressive strength, being determined by the manufactured density.

Products made from EPS are typically water resistant, tough and give very high impact resistance.  The air-filled structure has long term stable thermal conductivity, is non-toxic and chemically inert.  

Fungi and bacteria cannot grow on EPS due to it's properties.  

 

3. THE MOULDING OF EPS

The production of products made from EPS is done so in 3 stages...

1. Pre-Expansion

• A measured quantity of expanded polystyrene beads are put into a profoamer
• Steam is circulated through these beads as well as a small amount (usually around 5% by weight) of petane which is a blowing agent.  The beads are subsequently expanded by around 40 times. 
• The expanded polystyrene beads are transferred into a storage hopper...

2. Maturing

• The material cools and the pentane liquifies which creates a partial vacuum inside the bead
• The expanded polystyrene beads are stored for between 12-24 hours to aid the maturing and to allow air to diffuse into the beads

3. Final Forming

• The beads are then reheated using steam and the mould is filled with a pre-measured amount of expanded beads
• Steam is introduced into the mould circulating round the polystyrene beads, expanding them further by 10%.
• The steaming process stops and a vacuum is drawn to extract residual condensed water and heat. Additional water channels assist in cooling the mould

The video below shows the process...

As does this animation...

 

4. APPLICATIONS
 
4.1. PACKAGING

As EPS is made of 98% air, it is one of the lightest packaging materials in existance, and therefore adds very little weight to packaging, which means transport costs and fuel emissions are kept to a minimum. It's also hugely useful because it can be clearly marked with specific content like company logos, and labelling can easily be attached directly to the packaging.

A Selection of Products Made from EPS

 

Polystyrene foam is also tough, and the cellular matrix gives outstanding impact resistance and shock absorbency for the protection of products, making it an ideal packaging in many applications, includes protecting all kinds of electrical components, from mobile phones to fridge-freezers.

Expanded Polystyrene is Used to Package Goods to Protect them in Transit

 

It is also widely used to protect food and avoid damage during various stages of food production and shipment due to its properties being unable to grow fungi and bacteria. Its low thermal conductivity is utilised largely in the fish industry for the packaging and transport of fish products, and also in the medical field to transport vital transplant organs.

 

EPS is Often Used for Fishboxes as it Protects the Fish and Keeps it Cold (more info: www.fishboxes.info)

 
4.2. CONSTRUCTION
 

EPS Insultation Between Wall and Plaster

Due to its high levels of thermal insulation (from its light weight closed-cell structure, enduring strength, and long term structural integroty) EPS has been used in construction applictions since before the 's. 

EPS is widely used in walls, roofs, and floors, where its compressive strength can be tailored for specific systems such as beam and block construction, underfloor heating systems, and below concrete floor slabs.

It is also specified for void filling and, at higher densities, as a base for road or rail embankments where traditional fill materials are too heavy. The material has the advantage in city centres of reducing congestion and traffic with the delivery of large volumes of product more efficiently than hardcore.

Other specialist applications such as protection of foundations have also been developed.

 

EPS Floor Insulation Board: Technical Data

  Standard (White)     Low Iambda (Grey) Material EPS70 EPS100 EPS150 EPS 200 EPS 70 Compression Strength at 10% Deformation (kPa) 700 100 150 200 70 Thermal Conductivity (W/mK) 0.038 0.036 0.035 0.034 0.030

 

5. ENVIRONMENTAL FACTS

EPS has a low carbon impact because clean manufacturing technologies equate to minimal energy and water inputs with no production waste. The protective performance of EPS also helps to reduce wastage caused by goods that are broken or damaged in the supply chain, which saves energy, materials, and transportation costs.

The use of EPS also helps to prevent food wastage because due to its cellular nature, as it protects the food and avoids damage in the various stages of production and shipment from farm to fork, ensuring that many different foods reach the retailer or consumer in perfect condition. 

EPS is HFC, CFC, and HCFC free, with Pentane used as its blowing agent. Pentane has a low Global Warming Potential (GWP) of less than five - meaning the EU does not register pentane as a substance hazardous to human health or the environment.

As EPS is extremely lightweight it helps to reduce fuel consumption - when goods are transported compared to other heavier packaging materials.

Styrene, used in the manufacture of EPS, occurs naturally in many commonplace products including strawberries, beans, nuts, beer, wine, coffee beans and cinnamon.

The manufacture of EPS is a low pollution process. As steam is the key ingredient, and the water is re-used many times. There is no waste in the process as all cut off or rejects are re-used.

Only 0.1% of total oil consumption is used to manufacture EPS.

The carbon footprint of EPS is lower than many other packaging materials in use today.
 
6. END OF LIFE

EPS can be successfully recovered and recycled wherever facilities for recycling of EPS exist, which are becoming more widely available from mechanical recovery to solvent treatments, returning the polymer back to raw materials. EPS, sourced from packaging waste, is an ideal material for recovery schemes. Today it only represents 0.1% of municipal solid waste (MSW), although many believe it&#;s a lot more due to its bulky nature! Where the infrastructure for recycling is not currently in place, it is the ideal candidate to be submitted to energy from waste schemes.

The key benefit of using EPS for EfW is that it has a high calorific value (46,000 kj/kg) not dissimilar to natural gas at 48,000 kj/kg. There are also no toxic emissions in this method of waste management of EPS, as it is incinerated in modern plants at very high temperatures. The biproducts are therefore only steam, carbon dioxide and very low levels of non-toxic ash, which are less contaminating than a typical campfire - and in fact there is no credible evidence that EfW schemes have any impact on public health. 

EfW emissions are strictly controlled, and the UK Government&#;s &#;Waste Strategy for England &#; saw &#;no credible evidence of adverse health outcome&#; from EfW emissions.

 

7. MORE INFORMATION

Moulding Expanded Polystyrene (from Plastipedia)

Information on EPS Fishboxes

List of EPS Recyclers

Discover Channel: How It's Made Expanded Polystyrene

List of EPS Suppleirs
 

8. REFERENCES

1)  Plastic Historic Society: The History of IG Farbenindustrie   

2) The Inventors: Polystyrene and Styrofoam

3) National Inventors Hall of Fame (Otis Ray McIntire)

For more EPS foam shape moldinginformation, please contact us. We will provide professional answers.

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Understanding EPS Foam Shape Molding Machine

 

An EPS Foam Shape Molding Machine is a specialized piece of equipment used in the manufacturing process of Expanded Polystyrene (EPS) foam products. These machines are designed to transform raw EPS beads into various shapes and sizes, providing endless possibilities for packaging, construction, and artistic applications.

 

 

EPS foam, also known as Styrofoam, is a lightweight, versatile, and durable material with excellent insulating properties. Its popularity in various industries is attributed to its ability to withstand extreme temperatures, resist moisture, and absorb impacts effectively.

Durable
Excellent durability means it can effectively protect a wide range of items. There is no loss of strength in wet conditions, making EPS ideal for cold chain food. The fact that the material is moisture resistant also means that it meets the highest hygiene requirements.
 Protective packaging
Lightweight
EPS consists of 98 per cent air. Due to its extremely low weight, its use as a packaging material minimises the total weight of the product. This reduces transport costs compared to other packaging materials. In turn, this means that transport fuel consumption is improved and vehicle emissions are minimised. All of which helps to reduce global warming.
Thermal insulation
Thermal insulation helps keep food fresh throughout the distribution chain. It is widely used for packaging fish and seed trays, where low heat loss helps plant growth.

 

The Working Principle of EPS Moulding Machines

 

 

EPS Moulding Machines utilize steam as their primary heat source for molding EPS foam. The machines consist of a pre-expander unit, a molding chamber, a vacuum system, a steam chamber, and a cooling system.

 

 

First, the EPS beads are pre-expanded using steam in the pre-expander unit. These expanded beads are then fed into the molding chamber, where they are contained within a mold of the desired shape. The vacuum system ensures that the beads fill the mold evenly, resulting in a consistent product.

 

 

Once the mold is filled, the steam chamber applies heat and pressure to the beads, causing them to expand further and fuse together. This process is known as fusion molding. The cooling system then rapidly cools down the molded foam, solidifying its shape and making it ready for use.

 

 

The Benefits of EPS Moulding Process

 

 

The EPS moulding process offers numerous advantages, making it a preferred choice for many industries:

 

 

1. Versatility and Customization:

 

 

EPS foam can be molded into virtually any form, providing designers and manufacturers with limitless possibilities for product customization. From intricate packaging designs to complex architectural shapes, EPS moulding allows for precise replication of intricate details.

 

 

2. Cost-Effective Production:

 

 

EPS moulding machines offer efficient production rates, enabling manufacturers to produce large quantities of foam products in a shorter period. Additionally, EPS foam is relatively low-cost compared to other materials, resulting in cost-effective solutions for various applications.

 

 

3. Exceptional Insulation Properties:

 

 

EPS foam exhibits excellent thermal insulation properties, making it ideal for insulating walls, roofs, and refrigeration units. Its closed-cell structure and low thermal conductivity prevent the transfer of heat, keeping spaces cooler in summer and warmer in winter, thus reducing energy consumption.

 

 

4. Lightweight and Impact-Resistant:

 

 

EPS foam is lightweight, yet it has outstanding structural strength and impact resistance. This makes it suitable for packaging fragile items, protecting goods during transportation, and even constructing durable and earthquake-resistant buildings.

 

 

5. Environmentally Friendly:

 

 

EPS foam is 100% recyclable and does not contribute to environmental pollution. It can be recycled into new foam products or transformed into other useful materials, promoting sustainability and reducing waste.

 

 

Conclusion

 

 

EPS Moulding, facilitated by EPS Foam Shape Molding Machines, is a versatile and efficient process for creating various foam products. The wide range of benefits offered by EPS foam, including its versatility, cost-effectiveness, excellent insulation properties, lightweight, and environmental friendliness, make it a popular choice across industries.

 

 

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