Block Molding

PS Block molding is a means to an end.  Block molding is a technology to produce large blocks of solid EPS that is then hot wire cut and used for Insulation Boards for building and construction or Fabricated into Protective Packaging and Insulated shipping containers.

Unlike EPS shape molding, where a custom tool must be built, insulation boards cut to size can be fabricated into packaging and shipping containers.

The production of an EPS insulation board using block molding is achieved in the following stages:

1. 1. Pre-expansion of the EPS raw material to the required density
   2. Pre-expansion of the EPS raw material to the required density
   3. Storing the expanded material
   4. Foaming the EPS blocks
   5. Storage of the EPS block for drying and to reduce the residual stresses
   6. Hot Wire cutting the blocks into insulating boards for building, construction, and packaging

Environmental Scorecard

Used extensively in the construction industry due to its exceptional insulation properties, EPS has been found to yield exponential benefits to the environment by providing substantial energy savings and critical reductions in greenhouse gas emissions.   In fact, Life Cycle Analysis demonstrates an average savings of over 36 times the amount of energy expended when adding EPS insulation to the exterior walls in the U.S., and a reduction in global warming potential by nearly 60 times the CO2 equivalent of the emissions produced.¹