Moulding Expanded Polystyrene (EPS)

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Properties

Durable
The exceptional durability means that it can effectively protect a wide range of goods. There is no loss of strength in damp conditions, making EPS ideal for cool-chain food products. The fact that the material is moisture resistant also means that the highest hygiene requirements are met.

 

CD player with protective packaging

Lightweight
EPS is made up of 98% air. Due to its extremely low weight, its use as a packaging material minimizes the total product weight. This reduces transportation costs compared with other packaging materials. In turn this means that transport fuel consumption is improved and vehicle emissions are minimized. All contributing to lower global warming. Insulating
The thermal insulation properties help keep food fresh through the distribution chain. It is widely used to package fish and for seed trays where low heat loss assists in the growth of the plants.

Overview

Expanded polystyrene (EPS) is used for the production of a number of applications. However its major application is as a protective packaging for consumer electronic products and white goods. Its excellent thermal insulation and mechanical protection properties make it ideal to package fish and other foodstuffs. EPS also has applications in horticulture as seed trays.

The outstanding shock absorbency of expanded polystyrene packaging ensures the protection of a broad range of products. Moreover, its compression resistance means that EPS is ideal for stackable packaging goods. When safety is paramount, EPS comes into its own. It is used in the manufacture of children's car seats and cycling helmets, where its protective qualities, strength and shock-absorbency are vital.
 

The Production and Moulding Process

Unlike other thermoplastic processes, the production of EPS products requires that the raw materials be pre-conditioned prior to their final "tooled" moulding process.
The raw material (also known as "expandable polystyrene" or "bead") has a sperical shape and is similar to sugar in appearance.

The conversion process is carried out in three stages:

Pre-expansion
The tiny spherical polystyrene beads are expanded to about 40 times their original size using a small quantity of pentane (typically 5% by weight) as a blowing agent. This process involves the heating of beads, using a flow of steam, which causes the blowing agent to boil and thus a honeycomb of closed cells is formed. Maturing
As the material cools the pentane liquefies and a partial vacuum is formed inside the bead. The beads are returned to a holding tank for approximately twelve hours to allow the pressure differential to equalize, giving a stabilised granule. Final Forming
In this final stage the pre-expanded stabilized beads are reheated with steam in a mould. The final expansion takes place and the beads coalesce to give a shaped moulding. This can also be used to form large blocks which can be sectioned to the required shape as panels, boards, cylinders etc. In this final form the EPS is made up of 98% air.

The Machines and Tools

The components are formed in aluminium mould tools. These are generally of male and female form, with the shape between the two halves of the mould being the shape, being produced.

The mould tool is fitted into a press, which has the facility to introduce steam from behind each half of the tool. The steam is introduced through small slotted vents, which have been machined into the mould tool when it was manufactured.
 

Surfboards and body protection in moulded eps.
Head protection moulded in eps.
Medicine phials in protective packaging.

EPS and the Environment

EPS packaging is a thermoplastic polymer based on styrene, (which also occurs naturally in products such as strawberries and coffee beans.) It does not, and never has contained CFCs or HCFCs. The small proportion of hydrocarbon blowing agent used readily decomposes in the atmosphere, and as a result EPS does not have any adverse impact on the ozone layer.
 

About the BPF Expanded Polystyrene Packaging Group

The Expanded Polystyrene (EPS) Packaging Group is part of the British Plastics Federation and represents over 85% of the EPS moulding industry in the UK.

An objective of the Group is to raise awareness about the excellent combination of protection, cost-effectiveness and environmental performance that EPS can offer. Another objective is to increase the recycling of used EPS packaging and to promote awareness of existing recycling schemes through a programme of newsletters and seminars.

 

Contact a Plastics Packaging Supplier

If you are looking for a supplier of plastics packaging, please complete your details below and the BPF will send the detail, on your behalf, to the most relevant companies within the plastics industry who will contact you directly with more details.

 

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EPS Foam shape molding has revolutionized the manufacturing industry by offering a cost-effective and efficient solution for creating intricate shapes and designs. In this article, we will delve deeper into the process of EPS shape molding, exploring the role of EPS foam and the Molding Machine.

 

I. What is EPS Foam?

EPS (Expanded Polystyrene) foam, commonly known as Styrofoam, is a versatile material used in various industries for its exceptional insulation properties and lightweight nature. It is composed of individual polystyrene beads that are expanded through a steam heating process, resulting in a rigid cellular structure.

 

II. Understanding EPS Shape Molding Machine:

The EPS Foam Shape Molding Machine is an integral part of the manufacturing process. It is designed to heat, shape, and cool the EPS foam, enabling the creation of complex forms. This machine consists of several components, including:

A. Pre-expander:

The pre-expander is responsible for expanding the polystyrene beads by injecting them with steam and a blowing agent. This prepares the EPS foam beads for the molding process by increasing their volume and reducing their density.

 

B. Block Molder:

After pre-expansion, the expanded polystyrene beads are molded into large blocks. These blocks serve as the precursor to the final molded shapes. The block molder takes the expanded beads and molds them together by applying heat and pressure, resulting in solid blocks of EPS foam.

 

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C. Shape Molding Machine:

The shape molding machine is the heart of the EPS shape molding process. It takes the pre-molded foam blocks and shapes them into the desired forms using molds or tooling. The machine's automated process includes the following steps:

1. Loading the Mold:

The pre-molded foam blocks are loaded into the shape molding machine. The machine uses a conveyor system to transport the blocks to the mold.

2. Steam and Heat Application:

The mold is closed, and steam is injected to heat the foam. The heat softens the EPS foam, allowing it to expand and fill the mold cavities completely. The precise control of temperature and pressure ensures accurate shaping.

3. Cooling and Solidification:

Once the foam has expanded and occupied the entire mold, the cooling process begins. Cold air or water is circulated through the mold to rapidly cool and solidify the foam. This step ensures dimensional stability and accelerates the production cycle.

4. Mold Opening and Product Removal:

The mold is opened, and the shaped foam product is ejected using either mechanical or pneumatic systems. The product is then conveyed to the next stage of the manufacturing process.

 

EPS / EPP Foam Packaging Shape Moulding Machine

 

III. Advantages of EPS Shape Molding:

EPS shape molding offers numerous advantages that contribute to its widespread use in various industries:

A. Design Flexibility:

The versatility of EPS foam shape molding allows for the production of intricate shapes and forms that would be difficult or costly to achieve with other manufacturing methods. It enables designers to bring their creative visions to life.

 

B. Lightweight and Insulation Properties:

EPS foam is inherently lightweight, making it ideal for applications where weight reduction is essential. Additionally, its excellent insulation properties make it suitable for industries requiring thermal or sound insulation, including construction, packaging, and automotive.

 

C. Cost-Effective and Efficient Production:

EPS shape molding offers cost efficiency due to its ability to produce large volumes of foam products in a short time. The automated process reduces labor and energy costs, resulting in competitive pricing for end products.

 

D. Eco-Friendly Material:

EPS foam is 100% recyclable and environmentally friendly. It can be reprocessed into new foam products or transformed into other useful materials, minimizing its impact on the environment.

 

Conclusion:

EPS shape molding, facilitated by EPS foam shape molding machines, has revolutionized the manufacturing industry. This process provides a cost-effective, efficient, and environmentally friendly solution for creating a vast array of foam shapes. As industries continue to evolve, EPS shape molding will undoubtedly play a crucial role in meeting their complex manufacturing needs.

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