Expanded Polystyrene (EPS) is a white foam plastic material characterized by its excellent lightness and high strength. It is produced from solid polystyrene beads, which are expanded by steam and expanded to create a strong and durable foam, these expanded cells occupy approximately 40 times the volume of the original polystyrene pellet and with a second heat treatment, which is done using a mould, large blocks of EPS can be formed into specific custom shapes. EPS is widely used for packaging and construction because of its protective and insulating properties. It is a rigid closed-cell foam material that offers high thermal insulation performance and is moisture resistant and is produced from two main components:

1. Styrene, which forms the cellular structure of the material, giving it its characteristic strength and elasticity.
2. Pentane, which is used as a blowing agent, helping to swell the polystyrene beads and create the foam.

Both styrene and pentane are hydrocarbon compounds obtained from oil and gas by-products, EPS is 98% gas and is recyclable. It is a very lightweight material with the following advantages:

1. Excellent Insulation: Provides high levels of thermal insulation performance, making it ideal for use in construction and refrigeration applications.
2. Vibration resistance: Its cellular structure offers excellent shock absorption, protecting sensitive products during transport.
3. Ease of Configuration: Can be formed into various shapes and sizes through heat treatment, making it ideal for custom packaging and manufacturing applications.
4. Lightweight and Durable: Despite its low weight, EPS is very durable and can support large loads without losing its structural integrity.
5. Economic Efficiency: Its low production costs and durability make EPS a cost-effective choice for many industries.
6. Recyclable: Due to its recyclability, EPS helps to reduce waste and protect the environment.

One of the challenging limitations of polystyrene foam is its low operating temperature, which is around 80°C. This fact must be taken into account when selecting the material for applications requiring high temperature resistance.

Expanded Polystyrene (EPS) has an interesting history dating back to the beginning of the 20th century. The development and evolution of this material has significantly influenced many sectors, from packaging to construction.

Home Development:

1. Invention of Polystyrene: In 1839, the German pharmacist Edward Simon accidentally discovered polystyrene when he tried to synthesise a new pharmaceutical product by accident.
2. Commercial Development: In 1930, the German company BASF developed the first commercial polystyrene, using a polymerisation process that converted styrene into polystyrene.

Introduction of EPS:

1. Creating the EPS: In 1950, BASF developed expanded polystyrene (EPS) using expanding agents such as pentane, which enabled the production of a lightweight, foam material with excellent thermal insulation properties.
2. Commercial Availability: EPS was commercialized by BASF as "Styropor", and soon became popular due to its ease of use and multiple applications.

Evolution and Use:

1. Expansion of Uses: Since the 1960s, EPS began to be widely used in packaging, insulation materials, and building components. The lightness, strength, and thermal insulation properties of EPS made it ideal for many industries.
2. Technological Improvements: Over the years, EPS production technology has improved, making the material even more efficient and environmentally friendly.

Modern Developments:

1. Environmental Consciousness: Nowadays, recycling and reuse of EPS have become important issues, with many companies developing innovative methods for processing and reusing the material.
2. Applications: EPS continues to evolve, with new applications in advanced technological fields such as energy-efficient construction and sustainable architectural solutions.

The history of EPS reflects the continuous progress and innovation in the field of materials, demonstrating how a simple polymer can be transformed into a multifunctional and environmentally sustainable material with global use.

The creation of expanded polystyrene is carried out in three stages, starting with the extraction and preexpansion of the product, followed by intermediate curing & stabilization and the final phase of final expansion & molding, and final quality control.

1. Pre-expansion: The raw material (in granules of 0.4-2.0 mm diameter) is heated in special machines called preexpanders with the help of steam at temperatures of 80 to 100oC and expanded. On expansion the density of the material drops from about 630 kg/m3 to 10-80 kg/m3 depending on the intended use. The tiny granules of the raw material swell up to 50 times. The pre-expanded grains consist of small closed cells containing air inside.
2. Intermediate Maturation & Stabilisation: EPS preexpanded granules are stored in ventilated silos which facilitate the escape of pentane from the inside and its replacement by air. During this stage the granules also expel any moisture they contain.
3. Final Swelling & Moulding: The stabilized expanded polystyrene granules are transferred to special machines such as block moulding or injection moulding presses where, with the help of steam, they are again expanded and agglomerated to take the form of a mould. In block presses this form is large blocks which are then cut into the form of slabs for thermal insulation uses and in moulding machines the final form is that of each mould.
4. Quality Control: Quality control is a critical stage in the production process, ensuring that the product meets the highest standards of quality and performance. Through advanced techniques and precise measurements, we confirm the accuracy, stability and durability of the product before its final delivery to the customer.

The material can be modified by adding additives such as flame retardant, which further enhances the fire resistance of the coating material. This addition leads to increased efficiency and safety, offering superior protection against flames and temperatures, and making the material suitable for applications requiring high safety standards when dealing with fire hazards.