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How is EPS Manufactured?

Expanded Polystyrene foam is manufactured from the by-products, or left overs, from the oil refining process. Nextgen Solutions may be a “Block Molder” of EPS which suggests we mold EPS into large blocks 36” x 48” x 120” in size. These blocks are then dig smaller usable sizes that change with the appliance. The outline below explains how FPM manufactures the EPS foam pieces and sheets you’re familiar. How is EPS Manufactured

The staple within the sort of resin or beads of styrene is bought. Each bead features a microscopic dot of Pentane formed into its center. This material is furnished in air tight bags. These bags keep the beads “fresh” by assuring that the Pentane within each bead can’t escape into the atmosphere and render the fabric.

These beads of Styrene are about the dimensions of a grain of salt and have an identical consistency. It’s crucial that the beads are stored during a tightly controlled environment where the quantity of Pentane within their plastic shell remains consistent.  Each step of EPS production requires strict adherence very tightly controlled quality standards.

These beads of resin are loaded into a machine called a “pre-expander”. It does exactly what the name implies. Steam is injected into the beads at 212 degrees F. the warmth accomplishes two things. The wall of every bead is softened and becomes flexible and therefore the increased temperature also causes the Pentane to expand within the softened beads. The beads brag like popcorn to 30 times their original size.

The next step is that the molding process. It’s at now that the individual expanded beads are molded into one, homogeneous block. This is often the foremost crucial stage within the production process and it’s essential that very strict internal control standards are adhered.

Once again, steam is employed to deliver heat to the method. A precisely measured quantity of beads is blown into a steel mold. Steam is then injected into the pre-expanded beads to heat the combination to 212 degrees F. This heat causes the wall of every bead to melt and therefore the remaining pentane within each bead expands. This expansion causes the beads to extend in size within the steel mold. This expansion increases the pressure and therefore the beads are forced together to make one block. The soft bead walls actually allow the beads to melt together into one solid block. At now the mold opens sort of a clam shell and therefore the block of EPS foam is removed.

After the block has been far away from the mold it’s carefully weighed and marked so it are often traced throughout the assembly process. Adherence to the right weight assures that the right “density” or “weight per cubic foot” is maintained. Nextgen is one among the few block molders who tests the block for correct fusion at now within the process. A needle is injected into the middle of the block and pressurized air is applied. The degree to which the block restricts the flow of compressed gas is a sign of the right amount of fusion between the individual beads within the block.

Another step within the production process is the perforation process. Immediately after beginning of the mold, the surface of every block is perforated with thousands of small holes. The aim of this step is to assist moisture to flee the freshly molded block. The molding process leaves a smooth skin on the surface of every block and therefore the perforator allows the moisture, a results of the steam, to more easily shake the block.

Once the blocks are molded, perforated, weighed, and tested for correct fusion, they’re moved to the “drying room”. Within this room the temperature is maintained at approximately 140 degrees F. There are large blowers that circulate the air within this room. These steps are designed to get rid of the maximum amount of the moisture from the block as possible. The increased temperature also helps to scale back any internal stresses which will exist within the block as a results of the molding process.

If flat sheets are desired, a series of wires are connected to a “slicer” with the right horizontal spacing to offer the precise dimensions needed. The wires are heated with current and melt through the froth leaving a smooth, consistent, surface.  If irregular shaped parts are required, a computerized contour cutter is employed to duplicate whatever shape has been programmed into the machine’s software. A spread of cutting techniques is employed to realize the numerous demands of our customers. How is EPS Manufactured

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