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.
"Our mission is to contribute to a more circular, sustainable economy in Europe by raising awareness of the economic, social and environmental benefits of EPS packaging."
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.
EPS insulation boards can contribute to building thermal performance when correctly specified and installed as part of a complete building system. By reducing heat transfer through the building envelope, they can help reduce energy demand for heating and cooling; results depend on the building design, climate, use, installation quality and energy system.
In packaging, EPS is used to protect electronics and other high-value goods from damage, and to support temperature control for perishable products such as fish, meat, fruit and vegetables. Its low weight, insulation and shock-absorption properties can be specified for the requirements of a particular product and transport route.
Finally, EPS is technically recyclable through mechanical, physical and chemical recycling processes, subject to the product design and the availability of suitable local collection, sorting and recycling infrastructure.
How is EPS Made?
Expanded Polystyrene (EPS) is composed of 98% air and only 2% raw material. When exposed to steam, the polystyrene beads expand to up to 40 times their original volume and can be compacted into any shape or moulded forms such as transport packaging, fish boxes, insulation blocks, bicycle helmets and much more.
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 (aka. “grey EPS”) has become increasingly popular. Encased in polystyrene, the graphite behaves like a mirror, reflecting heat and reducing the amount of thermal radiation that passes through the foam. Thanks to this innovation, grey insulation boards are up to 20% thinner while saving up to 50% of resources in production without compromising on insulation efficiency.
Primarily, 75% of EPS in Europe serves for thermal insulation in buildings, and globally, a third is used as packaging material. EPS's versatility also extends to the production of helmets, life vests, and even to model construction and electrical engineering.
Applications in Packaging
Expanded Polystyrene (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 fragile electronics and household appliances, as well as insulated packaging for perishable and temperature-sensitive products. 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.
Applications in Building & Construction
Expanded Polystyrene (EPS) is used as an insulation material in a range of construction applications. Its thermal characteristics, weight and ease of handling vary by product grade and intended use.
EPS insulation can be used in façades, internal walls, roofs and floors. When correctly specified and installed as part of a complete building system, it can contribute to the building’s thermal performance. Actual heating and cooling energy use and costs depend on the overall building design, installation, climate, operation and energy source.
Properties of EPS Packaging
Composed of approximately 98% air by volume, EPS is lightweight and can be moulded into protective packaging formats. Its low weight can support handling and transport efficiency, depending on the product and logistics system.
EPS packaging is technically recyclable through mechanical, physical and chemical recycling processes, subject to suitable local collection, sorting and recycling infrastructure.
EPS can absorb impact energy when correctly designed for the product and transport route. It is used to protect equipment and perishable goods during transport, and in specified protective products such as helmets and child seats.
EPS packaging can support temperature control for perishable goods such as fish and vegetables when used as part of an appropriate cold-chain system. Studies report temperatures below 5°C for up to 72 hours for specific container configurations and test conditions.
EPS packaging can provide compressive strength and cushioning properties when specified for the weight, stacking conditions and distribution route of the protected product. It is used for goods such as washing machines and other household appliances during transport.
EPS is moisture-resistant and can help protect the integrity of transported goods. For food applications, hygiene and food safety depend on the complete packaging, handling and cold-chain system, as well as compliance with applicable requirements.