How is polystyrene foam made? All about polystyrene foam: experience from practitioners

Polystyrene foam is used very widely - it is indispensable as a thermal insulation, finishing and packaging material. What is he? How is polystyrene foam produced, what raw materials and equipment are used? Let's find out!

What is polystyrene foam?

Foam plastics include all types of gas-filled plastics.

Distinctive features of the material:

• porous structure, which consists of closed cells;
• low density level;
• high sound and heat insulation properties.

The group of foam plastics includes:

• polyvinyl chloride material;
• polyurethane analogue;
• urea-formaldehyde foam;
• phenol-formaldehyde material;
• polystyrene analogue.

Expanded polystyrene is the most common material. I will describe its production. Expanded polystyrene was created in 1951 by the German company BASF. Then it received the brand name “styropor”.

Foam plastic for its main purpose is a thermal insulation material. It is 98% air. The gas is contained in many small, thin-walled polystyrene foam cells.

What raw materials are used?

Expandable polystyrene is used as a raw material for polystyrene foam.:

1. It is produced by suspension polymerization of styrene.
2. The process occurs when a pore-forming substance is added, which is a mixture of isopentane and pentane. The volume of the mixture in the material is 5-6%.
3. If the foam is intended for construction, then 1% fire retardant is added to the raw material mass. These are usually bromine compounds.

Polystyrene is produced in the form of granules. These spherical particles are treated with antistatic agents. They prevent the material from accumulating electrical charges during transportation. Processing also improves the processability of raw materials. Polystyrene granules in Russian are designated PSV (foaming polystyrene).

Brands, types of foam and raw materials vary from manufacturer to manufacturer. Therefore, before purchasing a material, read its symbol in the technical documentation.

1. EPS (expandable polystyrene), foaming polystyrene. This is the international designation for granules.
   FS (self-extinguishing polystyrene)- another possible marking.
2. PSB (suspension polystyrene foam without press)- this is the Russian designation for foam plastic.

PSB-S (suspension polystyrene foam, pressless, self-extinguishing)- another version of Russian markings.

After this designation there is a digital indication of the material grade by density.

Where is foam plastic used?

The use of polystyrene foam was determined by its technical characteristics. Both molded products made from foamed polystyrene and its crushed waste are used.

Foam boards are used in construction:

1. For do-it-yourself insulation of facades and interiors of buildings.
2. For the production of permanent formwork.

1. In sandwich panels.
2. As an insulating layer inside load-bearing structures (three-layer reinforced concrete panels or blocks, layered masonry).
3. As an insulating base under a screed for mastic or roll roofs.
4. For thermal insulation of ceilings and basements.
5. As protection against freezing of the road base.

Foam plastic is also used:

• in shipbuilding;
• in refrigeration devices;
• when arranging pontoons and floating piers;
• as packaging for food products and household appliances.

Due to its low price and easy processing, decorative molded foam products are now widely used:

• skirting boards;
• ceiling tiles;
• moldings, etc.

Production of foam plastic boards

The foam production technology includes the following steps:

1. Initial foaming of raw materials;
2. Aging of granules;
3. Their final foaming;
4. Sintering polystyrene foam into slabs.

Saturated steam is used as a coolant in the production of polystyrene foam.

Pre-foaming of granules

Pre-foaming of raw materials - This is the most important stage in the production of expanded polystyrene. It affects the quality of the final product:

. Before this, their required volume is determined.

Steam supply. It is supplied under pressure of 4-6 bar.

Foaming granules. At the same time, they increase many times in volume.

Stopping steam supply. This occurs when the granules reach a volume of one cubic meter.

1. Pre-foamer unloading. Delivery of foamed granules by pneumatic transport to the dryer and then to the holding hopper.

The production of foam plastic grades of different densities is influenced by:

• brand of raw materials, since polystyrene granules have different fractionations;
• volume of loaded granules;
• steam characteristics;

• the total volume of already foamed granules.

The density of the material is also affected by the time it remains in the pre-expander:

1. If the time period is too long, then the granules begin to crack. Therefore the density increases.
2. If the foaming period is short, then the foam will have a significant variation in its density. Therefore, you will have to reduce the temperature by supplying a small volume of air and reduce the power supply to the pre-foamer.

To produce lightweight grades of expanded polystyrene (8-12 kg/m³), repeated foaming is used. The granules loaded for the second time must be well saturated with air.

The storage time for raw materials before re-foaming should be 11-24 hours. The smaller the granule size, the shorter their ripening should be.

Drying and conditioning of foamed raw materials in a ripening bunker

1. The foamed raw materials are dried in dryers. To do this, heated air is supplied to them through a perforated pipe. Its temperature is +30-35 °C. The granules are then cooled.
2. The pre-foamed raw material is subjected to a slight vacuum. Therefore, the granules are sensitive to changes in the environment. To relieve internal stress from them, they are blown out by a fan into a storage hopper. There the raw materials are stabilized.

1. Based on the brand of raw materials used, its conditioning time can range from 11 to 24 hours.
2. The ambient temperature when keeping the granules should be +16-20 °C. If it is lower, then the duration of conditioning should be increased. In summer, at temperatures above +20 °C, the holding period should be reduced.

When foam granules are delivered to bins, their apparent density increases due to their collisions with the inner walls of the conveyor. When determining foaming parameters, this increase in density must be taken into account.

At the stage of aging the granules, due to the fact that the pressure inside the spheres is less than atmospheric, air enters them. Pentane and water are squeezed out of the raw material until it stabilizes.

The rate at which air enters the granules is affected by their fractionation, temperature and density. The same applies to the pentane extrusion rate. The blowing agent leaves larger granules more slowly than small ones due to their smaller area to mass ratio.

For optimal forming, it is necessary:

• for foam plastic with a density of 40 kg/m³ or more - add pentane to the raw material in a volume of 1.7-2.5%;
• if you need a material with a density of less than 40 kg/m³, the volume of pentane is 2.6-3.2%.

Molding slabs in block molds

1. After conditioning, the raw materials are delivered to block molds by pneumatic transport.
2. After this, it is treated with water steam. As a result, the granules expand again, forming foam slabs in the working chamber.
3. Next, the molded plate is cooled. To do this, a vacuum installation creates a vacuum inside the mold.
4. Then the plate is pushed out of the working chamber by a pusher. Based on the design of the form, it can operate from a pneumatic cushion or cylinder.

The most important point when supplying steam to the working chamber: You need to pump out a large amount of steam in a minimum period of time. For this purpose, it is necessary to remove air from the mold before applying pressure. This is done using a vacuum device.

When producing expanded polystyrene, you should constantly maintain a high temperature inside the block molds. Otherwise, steam consumption will increase significantly and it will become saturated. This will reduce the quality of adhesion of the granules to each other.

1. The finished slab exerts pressure on the walls of the block mold. It is approximately 80 kPa.
2. In order for the slab to be removed from the forming chamber without damage, the pressure must be reduced to approximately 10 kPa.
3. The period of time required to reduce the pressure of the plate (its cooling time) depends on the brand of polystyrene foam.

Foam manufacturers use two types of block molds: with closed and open working chambers.

The advantage of open forms- with their help you can produce slabs and blocks of unlimited length.

The advantage of closed working chambers- better performance.

Curing slabs

After molding, the foam slabs must be allowed to rest. Conditioning is necessary to reduce the moisture content of the material, as well as to remove the internal stress that appears during its production.

When curing the slabs, they undergo processes of saturating the material with air and equalizing the external pressure with the internal one. The same thing happens when aging pre-foamed raw materials. Molded slabs 12 to 24 hours at room temperature.

Cutting slabs into sheets

The molded blocks are sorted and then stored. After this, the production of foam plastic is completed by cutting the slabs into sheets of the required thickness. Blocks are cut on vertical or horizontal cutting machines using hot rheostatic wire.

The most common thickness of the resulting sheets:

• 2 cm;
• 3 cm;
• 4 cm;
• 5 cm;
• 10 cm.

Crushing industrial waste

Industrial waste is passed through a crushing plant. From there, recyclable materials are transported through a pneumatic pipeline into a storage hopper.

The resulting crumbs (its dimensions are up to 1.5 cm) are again used for the production of foam plastic. It is added to the foaming granules in a ratio of 1:10.

How to choose equipment for the production of polystyrene foam?

If you decide to make polystyrene foam yourself, you need to choose the appropriate equipment for the workshop. Select components of production equipment based on your planned volume of production.

For example, if the required amount of material is no more than 1000 cubic meters per month, you need a line with a capacity of 40 cubic meters per shift. She will be able to provide this volume of foam.

Please note that the calculated line performance may not match the actual one. It depends on the following points:

1. The most important factor- origin of raw materials: imported or domestic. With Russian pellets, productivity may decrease slightly.
2. Second nuance- brand of polystyrene foam you will produce. Thus, polystyrene foam PSB-12 has a density of less than 12 kg per cubic meter. Therefore, it can only be obtained by double foaming. This reduces line productivity.

It is better to choose equipment for the production of foam plastic that has high productivity. You should not operate a low-power line to the limit of its capabilities; it may soon fail.

How to choose a steam generator?

The source of steam is a steam generator (steam boiler). Its minimum productivity should be 1200 kg per shift. However, it is advisable to purchase a steam boiler of greater power. This will make it possible to further increase the productivity of the equipment.

According to the energy carrier used, steam generators are diesel, gas and electric. Each variety has its own advantages and disadvantages:

Plus of a gas boiler - the price of steam generated by it is minimal.

Disadvantages of a gas boiler:

1. Gas can be supplied to the steam generator only if there is a project agreed upon by Gorgaz. An employee of this organization must connect the boiler. In addition, the gas steam generator should be registered with Gostekhnadzor.
2. These devices are slightly more expensive than their electric and diesel counterparts.
3. They require mandatory installation of water treatment.

All these shortcomings are additional time and financial expenses.

Advantages of a diesel steam generator:

1. It's the simplest.
2. The device does not require a project or permission to connect.
3. The productivity of diesel generators can be from 1200 to 12,000 kg of steam per shift.
4. The boiler consumes 10-50 liters of diesel fuel per hour.

Disadvantage of diesel boilers - they also require water treatment to be installed.

Electric steam generators are also easy to install and operate. They are more compact than gas and diesel units.

Their disadvantage- they require significant power (minimum 150 kWh). Because of this, an electric steam boiler cannot be installed everywhere.

What to consider when purchasing a foaming agent

A pre-expander is necessary for the initial steam treatment of polystyrene granules. At this stage, the initial foaming of the raw material is carried out, then it is brought to the desired density.

Granules under the influence of saturated water vapor can increase in volume from 30 to 50 times. The density of future polystyrene foam boards depends on this indicator.

Continuous prefoamer- the most common type of device:

1. Polystyrene granules flow into it without interruption.
2. Already foamed raw materials are poured in a continuous flow through a gate, which can be adjusted in height.
3. Thanks to the different pouring heights and the rate at which the granules arrive, they are brought to the required density.

Cons of a continuous prefoamer- product instability and difficult density adjustment. To correct these shortcomings, the equipment is equipped with electronic temperature control and granule dosing units. These systems save raw materials and reduce the cost of expanded polystyrene.

For a continuous action foamer to operate, it is necessary to supply saturated water vapor to it:

1. Its costs at the foaming stage are low.
2. It is not always possible to regulate the volume of incoming steam.
3. In addition, not all steam generators provide the ability to simultaneously foam granules and form foam slabs. This reduces the capacity of the production line.

My instructions are to use an autonomous low-power steam boiler in a small workshop. It can be 15-30 kWh. It is highly desirable that the steam generator has the ability to regulate power.

Cyclic prefoamer not as common as its continuous counterpart. It has a different operating principle:

1. A measured volume of granules enters the foaming chamber.
2. Steam is injected there under pressure.
3. Under its influence, the raw material increases in diameter.
4. When the total volume of granules reaches a specified value, they are unloaded.

Advantages of a cyclic foamer- the density of the processed raw materials is stable.

Flaw- low productivity. This disadvantage is eliminated by production automation.

It is possible to obtain grades of expanded polystyrene with a density below 12 kg per cubic meter only by repeatedly foaming the raw material. This method requires high precision in processing granules. It is achieved by automating production and using blowing agents of both continuous and cyclic types.

Conclusion

Polystyrene foam can be produced from granules of various sizes and origins. There are different brands on the market in terms of density and thickness, so take this into account when purchasing material.

When choosing equipment for the production of polystyrene foam boards, consider its type, productivity, completeness and level of automation. This directly affects the volume and quality of the material produced.

The video in this article will help you better understand the topic. If something remains unclear to you, ask questions in the comments.

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Information: Foam plastic is one of the most popular thermal insulation materials, occupying about 10% of the entire thermal insulation market in Russia. The high demand for polystyrene foam is due to its low cost and excellent thermal insulation properties, which are 5 and 15 times higher than those of wood and brick, respectively.

The scope of application of polystyrene foam is very diverse:

• construction sector (thermal insulation material for floors, roofs, foundations);
• trade sector (packaging material for goods);
• the sphere of production of goods (production of furniture, refrigerators, life jackets, tailoring, etc.);
• shipbuilding (production of buoys, pontoons, boats);
• outdoor advertising.

How to start a foam production business

Business planning should begin with an assessment of the product market. According to experts, to start a business successfully, you need to have guaranteed demand. Despite the fact that the volume of construction is increasing, which naturally increases the demand for thermal insulation materials (by ~ 10% per year), the competition among foam plastic manufacturers is quite serious. In addition to the large number of small and medium-sized enterprises in Russia, the volume of polystyrene foam exports from China is growing from year to year.

However, the market is still far from saturated and favors the entry of new players. Entry barriers are not so high, and the total investment for creating a small line (40 m3 per shift) is about 800 thousand - 1.5 million rubles.

What equipment to choose for foam production

To create a mini-enterprise for the production of foam plastic, you will need to purchase:

• pre-foaming agent;
• automatic feeding and dosing system of granules;
• foamed plastic receiving hopper;
• block molds for making foam plastic;
• drying unit (fans);
• tables for cutting foam blocks;
• waste crusher;
• steam generator;
• pneumatic transport for transporting granules and control panel;
• Packaging equipment;
• industrial scales.

Raw materials needed for the production of polystyrene foam

The main raw material for the production of polystyrene foam is expanded polystyrene PSV-S in granules. Much depends on the quality of raw materials and their shelf life. So, the older the polystyrene, the longer the foaming process and the more difficult it is to achieve the required density of the foam granules.

The most popular brand of polystyrene foam is PSBS 25F, which has longer curing times than other brands (PSB-S15, PSB-S25, PSB-S50, etc.). Using this brand allows you to achieve a more even surface with fine granules, on which plaster and paint can easily be applied.

To produce 1m3 of polystyrene foam, about 15 kg of polystyrene is required. The cost of 1 kg of polystyrene depends on the delivery region and manufacturer. For example, the price of average quality Chinese raw materials is 60-70 rubles/kg. Accordingly, the cost of raw materials for the production of 1 m3 of polystyrene foam is: 70 rubles. *15 kg = 1050 rubles. To ensure the operation of one 8-hour shift with a productivity of 40 m3 of foam, it will take about 42,000 rubles. This is a significant initial expense when starting a business with little start-up capital. We must not forget about this when planning a business.

Foam production technology

The production technology of foam plastic includes such stages as: primary and secondary foaming, drying, curing in air, molding and cutting of finished products.

The detailed production process is as follows: First, the pre-expander is turned on and the required number of polystyrene granules is loaded. Then steam is supplied to the pre-foamer and when the granules reach the required level of foaming, the steam supply stops. The foamed granules are unloaded and transported to the dryer. After drying, the granules are fed into a bunker, where they are stored for 12 hours. Next, the aged granules are loaded into a block mold, where they are vacuumized. The granules are kept under pressure for a certain time, after which the pressure is released and the block mold is cooled. Then, using a pneumatic pusher, the finished block is unloaded through the wall of the block mold. The division of finished foam sheets is carried out on a special machine for horizontal cutting. The resulting scraps after dividing the sheets are placed in a crushing plant, crushed to the required fraction, loaded into a hopper, where in a ratio of 1:8 they are mixed with primary foamed granules and reused.

Step-by-step plan for starting a foam production business

To open a workshop for the production of foam plastic, you will need a premises with an area of ​​at least 250 m2, including warehouse space. The ceiling height must be at least 5 m, the room must have good ventilation (due to the hazards of production), water supply, electricity connection (380 W) and heating (at least +15 degrees). At least 50 m2 of space is allocated for the warehouse of finished products, with mandatory insulation from the production workshop by fire-resistant structures. The warehouse must have a canopy that protects the foam from direct sunlight and precipitation. Monthly rent for a premises of this size, depending on the region, will cost 50-100 thousand rubles.

The required number of workers is calculated based on the line productivity - one person per 6 m3 of foam per hour. Two workers will be required to operate two shifts. Workers' remuneration is piecework-bonus, that is, it depends on the number of blocks produced per shift, on average - 50 rubles/m3. In addition to production personnel, at least one general worker (10 thousand rubles), an accountant (10 thousand rubles) and a sales manager (15-20 thousand rubles) are required.

Which taxation system to choose for a foam production business?

The organizational form of the enterprise is individual entrepreneur or LLC (legal entity). Individual entrepreneurship easier and cheaper to register than a legal entity. However, large wholesale companies prefer to work more with organizations rather than with individual entrepreneurs. Much also depends on production volumes - for small volumes, an individual entrepreneur is enough, then with an increase in production volumes and sales markets, it is definitely necessary to register an LLC. A legal entity can create branches and representative offices in other cities, and it is safer from a legal point of view - an LLC is liable for obligations only with property belonging to this organization, while an individual entrepreneur is liable with all property belonging to an individual (apartment, car, etc. .).

How much money do you need to start a foam production business?

The cost of purchasing equipment depends on the configuration, line productivity and taking into account delivery and installation, amounting to at least 800 thousand rubles (used ones are slightly cheaper). The most expensive components of the kit: steam generator - from 150 thousand rubles. and block form - from 100 thousand rubles. The cost of a full-fledged automated line with a capacity of over 100 m3 of polystyrene foam per shift amounts to several million rubles.

Let's calculate the economic efficiency of a foam plastic production enterprise with a productivity of 80 m3 per shift.

Initial data:

• Productivity per shift (per day) - 40m3
• Number of working days - 22;
• Production area - 250 m2, rental payments - 60 thousand rubles. per month;
• The number of production personnel is 2 people, the wage fund is 44 thousand rubles. (50 rub./m3);
• Payroll fund for other personnel: accountant - 10 thousand rubles/month, sales manager - 25 thousand rubles/month, general worker - 10 thousand rubles/month.

Capital expenditures: Purchase of a polystyrene foam production line worth 1.5 million rubles. The kit includes: a steam generator, a dryer, a block form BF 0.5, a pre-foamer, a receiving hopper with a control panel, tables for cutting blocks, an automatic granule feeding system, a waste crusher, a packaging machine, and industrial scales. The costs include delivery and installation of equipment at the customer’s premises.

Cost of raw materials: Expandable polystyrene PSV-S in granules will be used for the production of polystyrene foam. The price for 1 kg is 65 rubles. To produce 1m3 of PSB-25 foam plastic, 15 kg of polystyrene is required. The total cost of raw materials is: 15*65 = 975 rubles/m3.

Let's move on to calculating the total costs of polystyrene foam production per month, per shift and per unit of production.

According to the above calculations, the cost of production of 1 m3 of polystyrene foam is 1285.3 rubles.

How much can you earn in the production of polystyrene foam?

The net profit of the foam plastic production enterprise is 160,595.6 rubles per month. The profitability of production at such indicators is 14.2%, and the payback period for the equipment is 9 months. It should be noted that the indicators were calculated based on 100% sales of all manufactured products, which is 880 m3 of foam plastic per month.

Which OKVED code to indicate when registering a foam plastic production business?

Since polystyrene foam refers to foamed plastic, according to the all-Russian classifier of types of economic activities, when registering we indicate 25.21, which relates to the production of plastic products (plates, pipes, strips, profiles).

What documents are needed to open a business?

To open polystyrene foam production you will need the following package of documents.

Plan

Foam production

About the density of foam

Where do they buy raw materials for production?

How to make foam plastic with your own hands

Basic properties of polystyrene foam and its application

Styrofoam is a building material that consists of gas-filled granular masses. Today, polystyrene foam has found wide application in the repair and construction industry. In particular, it is used as a sound and heat insulating material for insulating rooms and finishing interior walls. First foam plastic made in Europe in beginning of the twentieth century, later its industrial production was established. The finished foam product has excellent heat and sound insulation properties, is resistant to temperature changes and precipitation, does not emit any harmful substances, is not subject to decomposition upon contact with microorganisms, is environmentally friendly and non-toxic.

The range of applications of this product is quite wide. Therefore, polystyrene foam quickly took a leading position in the building materials market. For example, foam plastic boards are used as thermal insulation and structural materials in the field of construction, car and shipbuilding, aircraft construction, and are also used as packaging and electrical insulating material

.

Foam plastic is a plastic, lightweight and easy-to-process material that is actively used by modern artists and designers in their art, animation and cinema. Using this material, you can create, for example, entire art objects of almost any shape and texture. In addition, you can cut out different figures from polystyrene foam, paint them with paints, and in the end you will get an original toy or a do-it-yourself fake from foam plastic, which will be a wonderful gift for family and friends on any occasion.

Foam production

Stages of foam production:

1. Foaming polystyrene foam. The raw materials are placed in a special container, where the material is treated with steam of low-boiling liquids.

As a result of foaming, the granules increase in volume from 20 to 50 times. After reaching the required level of granules, the steam flow stops and the working material is removed from the tank. The process itself takes about 4 minutes.

The next stage is drying. After foaming, the granules must be dried to remove excess moisture. Drying occurs under the influence of hot air, which comes from below, and continuous mechanical shaking. Drying time takes approximately 4 minutes.

3.

Vesting. After drying, the material is sent to a special aging bunker, according to the brand (15, 25, 35 and 50) where the aging process takes place. The entire procedure takes from 4 to 12 hours, depending on the size of the granules and the temperature of the environment.

Sintering or granule formation. The whole action takes place in a special block form, into which foamed granules are supplied. There, under high temperature and pressure, the granules are sintered and take the shape of a block. The process takes 6 – 12 minutes.

5. Maturing of blocks. Prepared blocks are sorted by brand and stored.

At first, the blocks may still release the remaining moisture. The ripening period of blocks takes from 12 to 30 days.6. Cutting foam blocks. On a special foam machine, string cutting of foam blocks into slabs of given sizes is carried out. Standard sizes are 20, 30, 40, 50 and 100 mm; other sizes can be determined by individual order.

The final stage is the processing of residual material. The production of expanded polystyrene is waste-free, since all residual materials are subjected to a crushing process and added to pre-foamed raw materials in proportions of 1:8. As a result, you get a finished product - polystyrene foam - a modern, competitive insulating material, which is undoubtedly in demand in the consumer building materials market .About the density of polystyrene foam. Finished high-quality polystyrene foam has evenly spaced granules of the same size. If the material is of low quality, such as PSB, in this case a fracture is formed at the points of contact between balls of different sizes. Expanded polystyrene consists of fine-cell granules sintered together. There are micropores inside the expanded polystyrene granules, and voids between the granules.

The mechanical characteristics of the material depend on the density. The higher the density, the higher the strength and the lower the water absorption, hygroscopicity, vapor and air permeability. The density of the foam depends on kilograms per cubic meter. Typically, for foamed polymers this coefficient is no more than 50, but often varies from about 15 to 35.

For example, in ceramic bricks the average density is close to 1,800 kg per cubic meter. Of course, the higher the density of the material, the higher the rate of transfer of thermal energy between its particles. For comparison, the thermal conductivity of the same brick is 18-20 times higher than that of foam plastic. On the other hand, its mechanical strength also depends on the density of the material, only in this case a direct relationship is visible: the higher the density, the stronger the material. If the material is repeatedly foamed, the density of the foam will decrease.

Perhaps for this reason, polystyrene foam is not used for the construction of load-bearing structures. As the name implies, foamed polymers are the result of a frozen foam polymer mass. Most of the foam is occupied by air, which is contained in plastic cells. Therefore, such insulating properties and low density.Where do they buy raw materials for production?Currently, the production of raw materials is established all over the world.

For example, such European manufacturers as BASF (Germany), Dvorex Sintez (Poland), Italian companies. Also worthy producers of raw materials for the production of polystyrene foam are Korea, China, Turkey and Russia. Moreover, according to the observations of other manufacturers, the quality of raw materials from the Chinese manufacturer has recently increased significantly, including the price/quality ratio. This fact encourages the European manufacturer to increase its competitiveness in the market, including the Ukrainian one.

The only drawback of cooperation with China can be considered that delivery times can take up to 1.5 months. How to make polystyrene foam with your own hands Preparing polystyrene foam at home is still not a safe process. This activity is best carried out in special rooms, for example in a workshop. And also prepare the necessary equipment in advance. All you need is polystyrene in the form of granules (they are quite small, so they are popularly called beads) and special equipment. To make polystyrene foam with your own hands, you need a sufficient number of small polystyrene granules. After which, these balls should swell and stick together.

This procedure is carried out by treating polystyrene granules with hot steam. As a result of this heating, the granules will begin to swell. After the granules swell, they will begin to release gas, which will push them towards each other. At the next stage, the granules are connected to each other, taking the shape of the container in which they are located.

After the resulting mass has cooled, the foam can be considered ready. But it should be borne in mind that the quality of such foam, prepared with your own hands, can be very mediocre. To produce high-quality polystyrene foam, it is necessary to use special equipment that will provide all the production technology. And besides, experiments with such high temperatures in domestic conditions can harm not only health, but also the living space itself. Preparatory work The production of expanded polystyrene, which is one of the types of foam plastic, requires the presence of an appropriate room.

Styrofoam blocks are empty boxes made from polystyrene foam. The size of such a block is 25 cm in height and width and 95 cm in length. It is worth remembering that although this process is simple, it is classified as chemical and is accompanied by the release of volatile formaldehyde substances. Having reached a certain concentration, they can poison both the manufacturers themselves and everyone around. Scheme and equipment for the production of foam plastic: 1 - raw materials; 2 - pre-foamer; 3 - aging bunker; 4 - block form; 5 - finished products; 6 - cutting foam blocks; 7 - pneumatic transport; 8 - steam receiver; 9 - compressor; 10 - steam generator; 11 - waste crusher. Making polystyrene foam with your own hands must be accompanied by very good ventilation. Therefore, it will not be possible to develop the production process in a city apartment. A separate room is needed.

A hangar or barn on a summer cottage, located away from residential premises, is best suited for this purpose. You will also need certain equipment that will have to be installed in this room. To produce expanded polystyrene we will need: granulated polystyrene; steam generator; steam accumulator; compressor; hopper for aging granules; mold for forming blocks; pneumatic transport; machine for cutting the finished product into slabs; check scales; measuring utensils. Dimensions of a polystyrene block. To purchase equipment you need spend approximately 500 thousand rubles.

Therefore, organizing the production of expanded polystyrene should only be done when a sufficiently large volume of products will be produced. For personal consumption, the production of the material is unprofitable. The production process is preceded by the purchase of raw materials. In most cases, polystyrene granules are sold in bags that weigh up to 25 kg. The main differences lie in size, product quality and country of origin.

In many ways, the latter factor plays a decisive role in the quality and consumer properties of the finished product. The smaller the size of the material granules, the harder and denser polystyrene foam can be obtained from them. In the process of making products with your own hands, it is necessary to take into account the duration of steam treatment and a number of other production technological nuances. In particular, you need to pay attention to the manufacturing date of the purchased raw materials. For granules that have been in storage for a long period of time, the foaming process takes much longer.

Production technology

Some types of polystyrene foam wall blocks: Monolithic: 1 - row, 2 - end. Collapsible: 3 - 200 mm wide, 4 - 300 mm wide. The polystyrene foam manufacturing process itself is divided into several successive stages. To carry out this work with your own hands you need: hot steam; electrical energy with a voltage of 380 V; cold water. First, the granules are poured into a pre-foaming container with your own hands, where they are treated with hot steam at a temperature of 120-150ºC.

Steam is supplied to the system under pressure from 0.9 to 4.5 atmospheres. Its formation occurs in a steam generator that runs on solid or liquid fuel. To accumulate a sufficient amount of steam, a steam accumulator is used, where it is previously supplied from a steam generator. Already from it, steam enters the pre-foaming tank. Under the influence of hot steam, polystyrene granules begin to increase in volume. During this process, careful monitoring is necessary.

Control weighing of a certain volume of manufactured products is used. To carry out this work, you will need check scales and measuring utensils. After reaching the required density, foam granules from the pre-foaming container are fed into a special hopper for drying. Drying of the material occurs using air heated to a temperature of 60-65ºС.

Then it is moved to another bunker, intended for aging the finished product. In this bunker, the process of product stabilization takes place. The expanded granules absorb moisture. For this reason, drying is necessary for an effective stabilization process. During aging, the final formation of the properties of the granules necessary in future blocks of expanded polystyrene occurs.

The time of this process depends on the size of the granules and the ambient air temperature. Flooring device using ceiling polystyrene foam blocks: 1 - ceiling polystyrene foam blocks, 2 - mounting metal beams, 3 - rib reinforcement, 4 - reinforcing mesh between the ribs, 5 - mounting support stand (1 rack per 1 m2 of floor), 6 - ordinary wall blocks, 7 - additional blocks. Next, you can proceed to the main process, which consists of baking and molding polystyrene foam blocks. In this process, it is necessary to use pneumatic transport, with the help of which the aged granules are fed into the molding container . After this, hot steam from the steam accumulator begins to flow into it. Under its influence, the block product is independently baked. The quality of the finished foam is directly affected by both the temperature and pressure of the steam, and the duration of its supply.

After the process is completed, the hopper doors open and the resulting block is taken out. Depending on the brand of polystyrene foam, the entire process of baking with your own hands takes from 5 to 10 minutes. The finished blocks are sorted by brand with your own hands and stacked in a dry room. And it must be in a vertical position. The seasoned block is divided on a special machine into sheets of a given thickness.

The most popular sizes of foam sheets are 20, 30, 40, 50 and 100 mm. In a modern machine for horizontal cutting, strings are installed that make it possible to divide a block into several sheets at once, cutting off excess from the edges of the blanks. The finished sheets are cut using vertical cutting with your own hands. If necessary, the blanks can be divided into sheets of the required sizes.

Expanded polystyrene can not only be purchased ready-made, but also made with your own hands. This does not require sophisticated equipment. Real benefit from such work is possible if large-scale production is planned, for example, when building a house. If you need to insulate a couple of walls, then it is better to buy polystyrene foam. Thanks to its thermal insulation properties, polystyrene foam can be used as external thermal insulation of the roof, foundation and walls.

Preparing for work

To make polystyrene foam with your own hands, you will have to do a number of preparatory work in order to then do everything quickly and efficiently. Products can be made in the form of slabs or blocks.

It all depends on which material is more convenient to use for the job. For example, slabs are used for insulation; they are glued to the surface. To construct any structural forms or for formwork, the use of blocks is required; they are additionally reinforced.

After forming, the blocks have the following dimensions:

width 25 cm; height 25 cm; length 95 cm.

Expanded polystyrene is 98% air, it is lightweight and inexpensive.

The process itself, how to make polystyrene foam at home, can be classified as simple, but demanding. The chemical reaction is accompanied by the release of formaldehyde volatiles. If you are not careful, cases of poisoning are likely not only for the manufacturer himself, but also for those around him.

Production scheme:

availability of raw materials (you need to purchase special granules, which are the basis for creating the material); a pre-foaming agent, with the help of which the mass is created; a bunker for working and aging the material; block molds for polystyrene foam; storage of finished products, cutting and sorting; pneumatic transport; steam generator ;compressor;steam receiver;waste crusher.

During manufacture, it is necessary to ensure that there is good ventilation to remove all vapors generated during operation. It is recommended that work be carried out in a separate room.

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Properties of expanded polystyrene.

Production planning:

Organization of the workplace, preparation of the necessary equipment. Purchase of granulated polystyrene, which will be used as the main raw material. The granules are poured into a container to create the material. The mass is saturated with steam at a certain temperature, cured, and baked into blocks or slabs.

Before starting work, you should ensure that you have the following tools and equipment:

container for mass; steam generator; steam accumulator (it is necessary to control the volume of steam); compressor; bins for granules, special forms for obtaining material of the required parameters; machine for cutting material; pneumatic transport; measuring utensils, scales for determining the finished volume.

Diagram of an expanded polystyrene panel.

An important step is the purchase of raw materials, i.e. polystyrene granules.

Today this is not so difficult to do; manufacturers offer bags of granules of 25 kg each. It is important to choose the right size, quality of mass, and country of manufacture. It is best to take raw materials from a trusted company whose product quality has the necessary properties.

The choice of granule sizes depends on what kind of polystyrene foam needs to be made.

The smaller the granules, the harder the material can be obtained. You should take into account how much time the pellets have already spent in the warehouse. The longer the raw material has lain in the warehouse, the more time is needed for foaming and steam treatment.

Failure to comply with the rules can lead to deterioration in quality, the material will ultimately not be entirely suitable for use, and this is a waste of time and money. It is necessary to correctly purchase raw materials, take into account the processing time, and fulfill all the conditions for baking. An important step is cutting, since the thickness of the slabs must be the same, discrepancies are not allowed.

Polystyrene foam is mainly used in the construction industry - about 85%. The remaining 15% goes to the production of packaging material, special life jackets, etc.

Analysis of the consumer market will help resolve the issue of how profitable it is to open a mini-plant for the production of foam plastic. The presence of competing enterprises is important. It is desirable that there are no competing enterprises within a radius of at least 100 km. However, the presence of polystyrene foam in stores cannot be considered as an indicator, since the product can be imported from any place.

The business plan must include all costs associated with production, organizational issues, as well as the profit expected to be received over a certain period of time. will allow you to understand how to build a business with minimal investment, but with maximum benefit.

Equipment for the production of foam plastic

Today, entrepreneurs can purchase production lines for various products, which include all the necessary and relatively inexpensive equipment.

Price

The foam production line is a complex equipment designed for continuous production of products. The price of equipment is set based on the possible volumes of goods produced.

Eg, line with a capacity of 20 cubic meters. per shift can cost about $7,000, a line with a productivity of 40 cubic meters - about $15,000, a line with a productivity of 100 cubic meters per shift - $25 thousand.

For example, a line with a complete set (40 m³ per shift) and a cost of $15,000 includes the following equipment:

• foaming agent for pre-treatment;
• special bags for bunkers;
• raw material conveyor;
• a bunker in which the products will be dried, as well as special fans;
• control panel for transportation;
• crushing equipment;
• molding barrels;
• Vacuum pump;
• cutting device;
• scales (to control the foaming process, as well as the total weight of the foam blocks).

Raw materials for foam production

Polystyrene foam is made from polystyrene PSV-S, produced in granules. The quality of the raw material determines the production time of the product, since the “older” the raw material, the slower the foaming process is and the more difficult it is to achieve the required density.

The diameter of polystyrene granules is no more than three millimeters. Nowadays, during the technological process of producing raw materials, antiprene is usually added to the composition, which prevents fire. However, the presence of this component must be checked with the supplier, since not all manufacturers add antiprene to their raw materials.

It is noteworthy that if the polystyrene was produced in domestic production, then the marking is marked with a “C” at the end, but if on Western equipment, then the letter “R”.

Foam production technology

The process of creating finished foam sheets consists of the following steps:

Foaming

The technology for manufacturing polystyrene foam begins with the fact that the raw material (finished EPS granules) is placed in a chamber where foaming occurs. The number of such procedures directly depends on the type of product that is planned to be obtained. For example, if you plan to produce foam weighing more than 12 kg, then one procedure will be enough. If you plan to produce light sheets weighing less than 12 kg, then several foaming procedures are necessary. At the same time, the processed raw materials after each procedure must last a certain time in the bunker.

aging

After foaming, the processed raw materials are moved to a special tank (hopper). There the raw materials are aged for 12 to 24 hours, since they must dry well. Also, during the aging procedure, the level of internal pressure stabilizes. After this, the raw material goes through the foaming procedure again, and then you can begin molding.

Molding

In block form, the prepared raw materials acquire a certain shape under the influence of steam. During the molding process, the structure of the raw material expands, due to which the mass sticks together.

cutting

After removing the foam from the mold, the blocks should rest for about 24 hours. When the material dries, the blocks are cut into sheets.

Polystyrene foam without waste, in which spoiled products or goods that do not meet any parameters are added to the raw materials at the stage of block formation. This method of work will reduce the cost of raw materials.

Room

A workshop for the production of foam plastic requires a room with high ceilings (about 5 m) and an area of ​​about 150 m2. Also a prerequisite is the presence of good ventilation and water supply necessary for technical needs. Heating (at least +15 degrees) and electricity (380 W) are also required.

The storage space should be approximately 60 m2. The warehouse is insulated with special structures made of fire-resistant materials. It is possible to place the warehouse under a canopy, with mandatory protection from direct sunlight and precipitation.

Considering the harmfulness of polystyrene foam production, as well as the fact that the material is highly flammable, the plant should be located at a distance of about 500 m from residential buildings.

Documentation

Before starting production, it is necessary to collect a set of documentation permitting this or that activity. Here we will talk in detail about what documents are needed for polystyrene foam.

Many entrepreneurs first register as individual entrepreneurs, paying a single tax. This is the best solution, since initially it is quite difficult to pay tax contributions in full. However, at any time you can expand production by re-registering it as an LLC, using a simplified taxation system.

You need to collect the necessary documents and also pay the state fee. In this case, a tax system is selected from five possible ones.

Then the code is defined OKVED. In this case, production corresponds to code 22.21“Production of plastic products (pipes, blocks, plates, sheets, profiles, etc.).” After this, you can begin collecting documents.

List of required documentation:

1. Passport (as well as a photocopy of the passport certified by a notary).
2. A copy of the TIN certificate.
3. Application for state registration.
4. Power of attorney for a representative who will provide documents for the entrepreneur.
5. Receipt for payment of duty.
6. Notification to apply the simplified taxation system (simplified taxation system), if it was chosen (two copies are needed - for printing about acceptance of the application, and also for the tax office).

All documentation is submitted to the tax office. After a few days (from 3 to 7), the entrepreneur will need to appear to receive documentation, as well as a registration sheet for starting work as an individual entrepreneur.

In addition, a current account must be opened at the bank. It is also necessary to obtain a permit to operate from the fire inspectorate, and to enter into agreements with organizations for the maintenance of production facilities (disposal and waste removal).

In addition, it is necessary to prepare a set of internal documentation:

• employee employment agreement;
• collective agreement;
• employee work instructions;
• safety regulations;
• work rules.

The production of polystyrene foam is carried out in accordance with the standards GOST 15588-86.

Staff

From 2 to 4 employees can work on one shift. When planning large production volumes, you can enter into an employment contract with a large number of people. The production of polystyrene foam takes place with the help of the following specialists:

• technologist;
• product sales manager;
• delivery driver;
• several workers (from 8 people if you plan to work in two shifts).

Accounting can be outsourced, which will help concentrate attention on production activities, as well as on the sale of goods, avoiding unnecessary hassle.

Profit and expenses

Foam plastic as a business is a fairly profitable enterprise, since polystyrene foam is one of the most popular building materials.

Cost price polystyrene foam is quite high, since the market value of one m³ of this material is about $20, and the manufacturing cost is about $10 (electricity, steam, raw materials).

For example, if a plant produces about 40 cubic meters daily, then the profit per month (when operating 24 days a month) will be about $20,000. However, approximately half of this amount (about 9,000 must be spent on monthly expenses). Net profit – 9000 – 10000 thousand.

Profitability production of polystyrene foam depends on how much product is produced, the pace of sales, etc.

Here is an approximate calculation of costs and income in order to create such a business from scratch:

1. Opening a business - about $25,000 (purchase of equipment, registration of activities, collection of documents, purchase of raw materials, etc.).
2. Expenses per month - about 9-10 thousand dollars (purchase of raw materials, wages, taxes, utilities), as well as rent - ($ 2.5 per 1 m2) - about 400 dollars per month when renting 150 m2 .
3. Approximate monthly revenue is about $9,000.

Based on this, we can say that the profitability of this is about 22%, the payback will be 5-6 months.

Total: 4 units, 2 suppliers, prices from 154,400 to 5,000,000 rubles.

Production technology

An overview of the foam production technology required for this equipment and a step-by-step description of the production process.

To produce polystyrene foam you need the following equipment:

• Steam generator
• Foaming agent (pre-foaming agent)
• Drying unit
• Aging bunker
• Compressor
• Sintering mold block
• Horizontal cutting machine

The equipment can be purchased as part of one production line or each unit can be purchased separately.

You will also need:

• Raw materials: foaming polystyrene
• Saturated steam, temperature 110-140 C
• Connection to the electrical network, voltage 380 V
• Cold water

Stages of foam production

1. Preparation of raw materials

Foam raw materials: foaming polystyrene is a product of the chemical industry. The characteristics of the resulting foam depend on its quality and shelf life. The older the raw material and the longer it has been stored, the more difficult it is to foam the granules.

The density of the resulting foam directly depends on the size of the original polystyrene granules: the smaller they are, the greater the density of the foam. Conversely, larger granules can produce less dense foam.

To produce polystyrene foam used in construction, a fire retardant, a substance that prevents combustion, is also added to the raw material.

The foam production process begins with the production of water vapor, pressure from 0.7 to 6 atmospheres and temperature from 110 to 170 C. A steam generator is used for its production. Depending on the availability of energy resources, the steam generator can be electric, diesel or gas. To obtain the maximum volume of steam, a steam accumulator is used.

2. Foaming granules

The amount of raw material required for a certain brand of foam is loaded into the pre-expander, and then steam is supplied.

Under the influence of steam, the original polystyrene granules foam, increasing in volume by 20-50 times. On average, to obtain one cubic meter of foamed raw materials, 15 kg of initial polystyrene is required.

The foaming process lasts 5-7 minutes. After foaming, the granules enter a drying unit, where excess moisture absorbed during steam treatment is removed from them.

3. Drying granules

In the drying unit, the granules are treated with warm air flows, freeing them from excess water while maintaining their volume. Streams of warm air are supplied from below, constantly mixing the granules.

In this case, wet granules fall down, and dry ones, on the contrary, rise up and, using a pneumatic transport system, are moved into storage bunkers.

Typically, the drying process lasts from 5 to 10 minutes.

4. Aging or stabilization of granules

The final stabilization of the granules takes place in the storage bins. The duration of this process depends on the volume of granules and the ambient temperature. The number of aging bins depends on the productivity of the installation, and their height and volume are determined by the height of the ceilings in the room.

In this case, polystyrene of different brands should be stored in separate bins. As a rule, the duration of aging can range from 4 to 12 hours. The stabilized granules are then sintered.

5. Baking polystyrene foam

Through a special loading hole, the block mold is completely filled with ready-made granules, which are supplied using air flows generated by a compressor.

The sintering process is carried out using steam supplied from a steam accumulator. The quality of sintering directly depends on the temperature and pressure of the steam, as well as the time of its supply.

The foam is then cooled using a vacuum unit and takes the desired shape. The entire process, depending on the brand being baked, lasts from 5 to 12 minutes.

6. Cutting foam

After completion, the installation door opens and the block is pushed out by a pneumatic pusher onto the receiving table. The finished blocks are laid vertically and kept for several hours or days. At this time, they give up excess moisture and undergo a stabilization process.

The foam blocks are then cut into slabs of the required thickness using a horizontal cutting machine. Grooves and protrusions can be made on them. The resulting scraps can be recycled.

Finished slabs are packaged and sold.