Page 1 of 3
____________________________________________________________________________________
Styropor Grades & Processing Guide
February 2011
____________________________________________________________________________________
MP-Grades Recommended Processing Parameters
Grade
Model Size
(mm)
Min. Wall
Thickness
(mm)
Application
MP103
1.30 - 1.80
14
Low Density Block
MP303G
MP303
MP403
1.00 - 1.30
0.70 - 1.10
0.45 - 0.70
10
Mid Density Block
Fish/Produce Box
Shape Moulding
Shape Moulding
Shape Moulding
Density
(g/l)
Expanded
Size (mm)
Preexpansion
Steam Pressure
(Bar)
Intermediate
Aging (Hours)
15
4.6 - 6.4
0.25 0.30
10 14
20
4.2 - 5.7
0.15 0.20
14 20
25
3.9 - 5.4
0.05 0.10
20 26
16
3.4 - 4.5
0.25 0.30
6 10
20
3.2 - 4.2
0.15 0.20
10 16
25
3.0 - 3.9
0.10 0.15
16 22
30
2.8 - 3.6
0.05 0.10
22 28
20
2.3 - 3.5
0.15 0.20
49
25
2.1 - 3.3
0.10 0.15
9 14
30
2.0 - 3.1
0.05 0.10
14 19
40
1.8 - 2.8
0.05 mix with Air
22 27
20
1.5 - 2.3
0.15 0.20
48
25
1.3 - 2.1
0.10 0.15
8 12
30
1.2 - 2.0
0.05 0.10
12 16
45
1.0 - 1.7
0.05 mix with Air
20 24
Density
(g/l)
Expanded
Size (mm)
Preexpansion
Steam Pressure
(Bar)
Intermediate
Aging (Hours)
15
4.6 - 6.4
0.25 0.30
20 24
20
4.2 - 5.7
0.15 0.20
24 28
25
3.9 - 5.4
0.05 0.10
28 32
16
3.4 - 4.5
0.25 0.30
16 20
20
3.2 - 4.2
0.15 0.20
20 24
25
3.0 - 3.9
0.10 0.15
24 28
MF-Grades Recommended Processing Parameters
Grade
Model Size
(mm)
Min. Wall
Thickness
(mm)
Application
MF162
1.30 - 1.80
12
Low Density Block
MF262
MF362
MF462
1.00 - 1.30
0.70 - 1.10
0.45 - 0.70
10
Mid Density Block
Shape Moulding
Mid Density Block
ShapeMoulding
High Density Block
Shape Moulding
30
2.8 - 3.6
0.05 0.10
28 32
20
2.3 - 3.5
0.15 0.20
12 16
25
2.1 - 3.3
0.10 0.15
16 20
30
2.0 - 3.1
0.05 0.10
20 24
40
1.8 - 2.8
0.05 mix with Air
28 32
20
1.5 - 2.3
0.15 0.20
8 12
25
1.3 - 2.1
0.10 0.15
12 16
30
1.2 - 2.0
0.05 0.10
16 20
45
1.0 - 1.7
0.05 mix with Air
24 28
Page 2 of 3
Specialty MF-Grades Recommended Processing Parameters
Grade
MF312
Peripor
MF300
Model Size
(mm)
Min. Wall
Thickness
(mm)
0.70 - 1.10
0.70 - 1.10
Application
Fast Cycle
Block/Shape Moulding
Water Resistant Grade for
Board Moulding
Density
(g/l)
Expanded
Size (mm)
Preexpansion
Steam Pressure
(Bar)
Intermediate
Aging (Hours)
20
2.3 - 3.5
0.15 0.20
49
25
2.1 - 3.3
0.10 0.15
9 14
30
2.0 - 3.1
0.05 0.10
14 19
22 27
40
1.8 - 2.8
0.05 mix with Air
20
2.3 - 3.5
0.15 0.20
49
25
2.1 - 3.3
0.10 0.15
9 14
30
2.0 - 3.1
0.05 0.10
14 19
40
1.8 - 2.8
0.05 mix with Air
22 27
Peripor Water Absorption Charts
bulk density 20 kg/m3
bulk density 30 kg/m3
Thermal conductivity of expanded EPS as a function of
moisture content for bulk densities of 20 kg/m3 and 30 kg/m3
Water absorption in diffusion tests DIN-EN 12088 (Bulk density
30 kg/m3, Board thickness 90 mm)
Other Recommendations
Influence of Beads Size
Smaller beads will lose pentane faster when compared to the bigger beads. Precautions must be taken
when processing MP403/MF462 as the processing window is narrow. Intermediate aging time in the silo
cannot be more than 24 hours except for very high density.
Influence of Pentane
Pentane functions as the expanding agent during pre-expansion and later as softener during moulding. It
is very important to have the optimum pentane content during the moulding process.
High pentane content of the pre-expanded beads will make the surface close very fast during moulding.
This will cause poor internal fusion, bulging, long cycle time or crack after demoulding. On the other hand,
low pentane content will cause the beads to become hard. Under this condition, it would be difficult to
achieve good internal fusion.
As a general rule of thumb during moulding;
Higher pentane content lower steam pressure (0.7 0.9 bar)
Lower pentane content higher steam pressure (0.9 1.3 bar)
Adjust the internal fusion with steaming time
Page 3 of 3
Cost Saving Tips
Approximately 98% of steam consumption during moulding was used to heat up the mould (tool) and only
2% was consumed for fusion.
In order to optimize the moulding process, demoulding at the highest temperature possible would be the
best practice to save energy. Styropor could be demould at 80 oC when certain processing conditions were
present. As for standard EPS, the demoulding temperature could be in the region of 65 75 oC.
Important conditions to achieve high demoulding temperature;
Good vacuum pressure (-0.4 bar minimum)
No leaking of the mould
Sufficient cooling for the vacuum pump
Evenly distributed water spray to ensure no hot spot at the mould
Minimum time of water spray. Normally only a few seconds to loosen up the foam by thermal shocking.
Steam saving calculations:
Formula : m = Gwz x (r/c) x t
Symbol
Gwz
Description
Unit
Weight of tool + 50% share weight of steam chest
Value
kg
100
o
Specific heat value for Aluminum
kJ/(kg x C)
0.942
Vaporization heat value of water
kJ/kg
2264
Difference in demoulding temperature
Demoulding temperature of Styropor
80
Demoulding temperature of Standard EPS
75
Steam Savings/Cycle
kg
0.21
Fuel oil required to produce 1 kg of steam
litre
0.10
C
C
Fuel oil cost
USD/litre
0.50
Cost of steam
USD/kg
0.05
Savings per cycle
USD/kg
0.010
Estimated material per cycle
kg EPS
0.30
USD
35
SAVINGS PER MT. STYROPOR
Note
The information submitted in this publication is based on our current knowledge and experience. In view of
the many factors that may affect processing and application, these data do not relieve processors of the
responsibility of carrying out their own tests and experiments; neither do they imply any legally binding
assurance of certain properties or of suitability for a specific purpose. It is the responsibility of those to
whom we supply our products to ensure that any proprietary rights and existing laws and legislation are
observed.
Prepared by Ng Yim Ming
BASF (Malaysia) Sdn. Bhd.
Lot 143, Jalan Cecair
Johor Port FTZ
81700 Pasir Gudang
Johor Malaysia.
Tel : +607 253 5000
Fax : +607 253 2007
All Rights Reserved
Printed: 30-Oct-09
