Page 1 of 3

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Styropor Grades & Processing Guide

February 2011

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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