Tour Our Facility - EPS

Molding of EPS Blocks

During the molding process the expanded beads are formed into a solid block. Dyplast Product's state-of- the-art equipment precisely measures the amount of beads introduced into the chamber. When the chamber is full, the initial step is to create a vacuum in the chamber. This is followed by the introduction of steam which flows evenly over all beads, softening the polymer structure of the bead surface. As additional steam is introduced, the latent heat from the steam and subsequent pressure increase cause the beads to further expand.

The expanding beads fill the voids between them and fuse together into a polyhedral type solid structure. The computer subsequently releases the pressure at a pre-determined point that varies depending on the desired density of the EPS block.

The final step in the process is to recreate a slight vacuum in the chamber to promote cooling. This additional step draws residual moisture from the block, thereby creating a drier and more integrally fused block of EPS. The block is then ejected from the mold and another cycle begins.