EPS - A reliable and light material
Lightweight and versatile, Expanded Polystyrene (EPS) is known for its insulation and protective properties.
EPS is used in applications including building insulation and packaging. It is composed primarily of air by volume and can be technically recycled through mechanical, physical and chemical processes. Actual collection and recycling depend on the application, product design and local infrastructure.
"EPS supports a range of recycling pathways, including mechanical, physical and chemical processes. Continued progress in collection and recycling systems can help expand these options across applications and regions."
A short story of EPS
The history of Expanded Polystyrene (EPS) started in 1949 when an accidental discovery by Fritz Stastny (BASF) led to the creation of a lightweight, cost-effective material. By 1952, EPS was introduced at the Düsseldorf plastics trade show, setting the stage for its widespread use. In 1954, its use in building insulation marked its introduction into construction. A short three years later, in 1957, the first ETICS was installed with EPS insulation and remains in service today. The leap to mass production followed in the late 1950s with facilities opening in Brazil and France. Notably, in 1962, EPS was chosen to transport the Mona Lisa thanks to its outstanding protective qualities.
1997 marked a big shift for EPS with the market release of “grey EPS”, which offers greater thermal insulation compared to white EPS in the construction sector. By 2020, the insulating properties of EPS became crucial for transporting COVID-19 vaccines globally, playing a big role in saving lives. Through these developments, EPS has demonstrated its versatility and importance, and remains in use in a range of applications.
When used as part of a building system, EPS insulation can contribute to the thermal performance of a building. Actual energy use and greenhouse-gas impacts depend on the building design, installation, climate, user behaviour and energy mix. In packaging, EPS can provide protection and temperature control for specified applications. EPS is technically recyclable in packaging and construction applications, subject to available collection and recycling systems.
How is EPS Made?
Expanded Polystyrene (EPS) is composed of approximately 98% air and 2% polystyrene by volume. When exposed to steam, the polystyrene beads can expand to up to 40 times their original volume and can be moulded into products such as transport packaging, fish boxes, insulation blocks and bicycle helmets.
EPS production begins with expandable polystyrene beads. These are pre-expanded with steam, then allowed to stabilise before moulding. The beads can be moulded into large blocks for cutting into insulation boards, or directly into specific shapes for packaging and other applications. By adjusting expansion, density and moulding, manufacturers can tailor EPS products to different uses.
Engineers continuously innovate to enhance EPS's protective, recyclable, and insulating qualities, ensuring its longstanding utility and efficiency. Insulation boards cut from this material are then bound with a flame retardant to ensure maximum fire safety, with a strict regard to high EU legislative standards.
In recent years, EPS insulation containing graphite has allowed new highs in resource savings (up to 20% thinner EPS boards and up to 50% less resource usage) without compromising on insulation efficiency.
Applications in building & construction
Expanded Polystyrene (EPS) insulation offers numerous benefits, making it ideal for various building applications. Lightweight and easy to process, EPS can be moulded and cut without special equipment, simplifying installation. Its low thermal conductivity ensures excellent temperature regulation, with consistent performance over decades due to minimal water absorption.
EPS is versatile, used in facades, roofs, and perimeter insulation, providing strong thermal and sound insulation. It meets stringent fire safety standards and maintains high durability with impressive compressive strength and moisture resistance.
Economically, EPS insulation reduces heating energy consumption, with renovation costs often recouped within four to ten years. It is also recyclable, supporting sustainability efforts. EPS enhances energy efficiency, aesthetic value, and climate protection, making it a superior choice for modern building insulation needs.
Applications in Packaging
EPS packaging is used where lightweight, insulating and protective properties are required. It can be moulded into shapes designed to hold, separate and protect products during storage and transport.
Applications include protective packaging for electronics, household appliances and fragile goods; insulated boxes for fresh food, fish and temperature-sensitive products; and packaging for pharmaceuticals, laboratory samples and other items requiring temperature control.
The appropriate packaging solution depends on the product, transport conditions, hygiene requirements and required level of protection. EPS packaging can be technically recycled through established processes, subject to its design and the availability of local collection and recycling infrastructure.
Properties of EPS
Composed of approximately 98% air, EPS is light yet strong, making it easy to handle and use in construction and packaging applications. Often described as “engineered air”, EPS combines low weight with mechanical performance.
As a technically recyclable material, EPS can be processed through mechanical, physical and chemical recycling routes. These routes can support material recovery where suitable collection and recycling infrastructure is available.
EPS insulation can contribute to the energy performance of a house when correctly specified and installed. The Fraunhofer Institute for Building Physics states that the service life of an ETICS can be extended considerably: “The life expectancy of the ETICS can be extended to a period of up to 120 years.”
Able to bear substantial loads over a prolonged period without significant deformation, EPS is ideal for a wide range of structural and insulation applications.
Able to effectively absorb impacts and shocks, EPS keeps products safe during transport and significantly reduces the risk of damage.
EPS provides thermal insulation that can help maintain interior temperatures when correctly specified and installed. It is used in building insulation and temperature-sensitive packaging.