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A publication on trends and applications
from Battenfeld Gloucester Engineering
December 2003
XPS and Foam Board
by German Laverde, Director of Marketing & Communications
with contributions by:
Mike Andrews – Battenfeld Gloucester Engineering
Nick King – SMS Folientechnik
Lydia Walder – SMB-DAVID
What is XPS?
Insulation Boards are made from several materials such
as polyisocyanurate, gypsum boards, PU foam boards,
and XPS. The term XPS refers to Extruded Rigid
Polystyrene Foam. The main market for XPS and some
of the other boards is thermal insulation in housing and
other construction. However, they can be used for
goods-protection as well. Proper insulation of a building
can substantially reduce fuel resource (i.e. oil, gas, etc.)
or electricity consumption for heating.
As a result of the production process, these boards are
composed of small tightly packed closed cells that
entrap a low thermally conducting gas, which
contributes to the insulating effect. This characteristic
gives the board water-impermeability properties as well.
XPS can be found in large hardware stores, and
depending on the producer, will have a color such as
pink, blue or green.
Photo #1: Insulation type foam board
TechLiner
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Abstract
Insulation Type Foam Board
Different materials can be and are currently being used for
insulation purposes - from fiberglass to cellulose and foamed
polymers, including Polystyrene (PS). The intent of all these
insulation materials is to achieve the highest thermal
resistance and compressive strength, and prevent heat
transmission from one surface to another. Thermal resistance
value identifying and differentiating one material from another
is often expressed as the R-value per inch of thickness
according to the American standards, or RD according to the
European standards.
Applications
Current Applications:
• Advertising displays, signs & decorative material
• Interior wall insulation applications
• Roofing insulation
• Foundation insulation
• Insulation under roads/railways/airport runways to
prevent permafrost from melting during the summer
• Waterproof protection
• Support for tile installation
• Home and industrial applications
• Refrigerated trucks for roads and rails
• Laminating industries
Potential Applications:
• Tanks and pools insulation
• Industrial freezers and cold rooms
And then, what
about EPS?
Although EPS can refer to extruded
polystyrene, it is commonly used to
designate Expanded Rigid Polystyrene
Foam. EPS is also used as insulation
material in roofs, walls and ceilings.
Additionally, it is used in civil engineering,
earthwork and road construction on
subsurfaces with low bearing capacity,
as is XPS.
EPS is produced by a different process
than XPS in that it is not extruded. As a
result, the appearance and physical
properties are different and the insulation
effect is lower than with XPS. Typical
3 adjustable calibrating plates set to the final
density-range for EPS is 10-35 kg/m
3 required thickness. Located after the
(0.62 - 2.18 lb/ft ).
How are XPS and EPS
produced?
In the XPS process, polystyrene pellets,
like those used to produce rigid sheet for
thermoforming, are melted and blended in
a regular tandem extrusion system. The
extruders pump the melted material
through a flat die after the foaming agent
(usually based on CO2 or
Hydrofluorocarbons - HFC) is injected and
homogenized in the primary extruder. The
foaming effect occurs as a result of the
change in pressure once the polymer
starts exiting the die. It is controlled as the
Photo #2: Foam board extrusion die and calibrating unit
EPS vs XPS
EPS
Closed cell foam
Permeable to water
Low capital investment
Lighter weight
Higher production cost (excluding
material costs)
High dimensional stability
Lower compressive strength
Higher thermal conductivity
Lower output production process
Non-toxic
extrudate or hot material expands between
plates are a train of rollers also helping to
control the growth and therefore the
thickness while transporting the material
forward towards the finishing stations (See
Photo #2).
Quality control measurements for flatness
and thickness are performed before the
boards are finished. The foamed product
must cool and mature before it is ready for
the finishing operation.
On the other hand, EPS is produced in a
different process, since the original
material is supplied as polystyrene beads
that already include a foaming agent such
as pentane. These beads are expanded
afterwards in closed molds by up to 50
times their original volume at temperatures
Photo #3: Foam board extrusion line
XPS
Closed cell foam
Impermeable to water
High capital investment
Heavier weight
Lower production cost
High dimensional stability
Higher compressive strength
Lower thermal conductivity
Higher output production process
Suitable for load bearing applications
around 212°F (100°C). The results are
compact foam in the shape of the mold
with a high content of air enclosed in many
fine cells that have excellent and durable
insulation properties.
Typical production
equipment for XPS
The specifications for a production plant
with an extruder capacity of 400–500 kg/hr
(880 - 1100 lb/hr) to produce foam board
are summarized in the table on the next
page.
Foam board is commonly produced in
equipment combining a single screw
extruder for melting and mixing, in tandem
with a secondary single screw extruder for
cooling and homogenizing. Sometimes a
twin screw extruder in tandem with a
single screw extruder is used to produce Typical Production Equipment for XPS
foam boards. Equipment suppliers claim
Product Polystyrene (XPS)
good mixing with this setup, however, the 3 3
Density 30 - 40kg/m 1.87 - 2.49 lb/ft
cost of the equipment can be an issue.
Extruder capacity* 400 - 500 kg/hr 881 - 992 lb/hr
Typical foam board extrusion line Panel length 1000 - 3000 mm 40 - 120"
components: Panel width - Extruder outlet max. 850 mm max. 33"
• Resin handling, blending and feeding - Finished 500 - 650 mm, 1200 mm 20 - 25.6", 47"
system Panel thickness 20 - 120 mm 0.79 - 4"
• Additives, color, physical and 160 mm free-foaming 6.3" free-foaming
chemical nucleants, and flame
Production speed 10 - 20 m/min 33 - 65.6 ft/min
retardants dosifying system
Equipment speed 0.5 - 25 m/min 1.64 - 82 ft/min
• Primary extruder
• Secondary extruder with cooling Max. pile height 550 mm 21.65"
type screw Operation height 1060 mm 41.7"
• Slit die Cutting capacity 16 cuts per minute by 1.25 panel length
• Calibrating unit *Extruders with a capacity of up to 3300 lb/hr (1500 kg/hr) are also available.
• Transportation system
• Finishing stations affect the physical properties of the board. difficult to open the die gap when making
Particularly when using CO2, high vapor thick boards. Thick boards made with CO2
pressure, poor solubility and poor thermal may show poor dimensional stability due
Processing issues when conductivity give a small process window, to lack of cooling and high skin/core

producing XPS boards lower outputs, higher density, higher

XPS boards were commonly produced
using foaming agents such as
Hydrochlorofluorocarbons (HCFC) 142b
and R22, giving a good combination of
compressive strength, thermal conductivity
and density.
In Europe, HCFC’s have been banned since
the end of 2002 and will be phased out
worldwide in developed countries by 2010.
Alternative gases such as HFC’s (70%
152a and 30% 134a) and CO2 are
considered replacements but adversely
thermal conductivity but better
thermal differences. Melt temperatures
have to be kept low as well because of the
compressive strength compared to HCFC potential for flame-retardant degradation
foamed board. Solvents are commonly that will damage the screws.
added when processing formulations with
CO2, to increase gas solubility and foam Extruded Foam Board can be obtained
cooling. without any coating or overlapped material
or with a reinforced cement layer as a
The process window is narrowed with HFC coating (See Photo #5). This allows the
gases and even narrower with CO2. This boards to be used as backboards or as
processing window involves the right support for tiles and other finishing
conditions for melt extrusion and cooling materials.
combined with obtaining the right
elongational viscosity for foam expansion.
Temperature and pressure control should
ensure that the solubility limits of the
foaming agents are not
exceeded. Solubilities
of CO2 have been
found to be very low
compared with HFC or
blends of different HFC
types.

Also, it has been found

that higher die
pressures are required
for CO2 and HFC’s due
to their low solubility
and high vapor
pressure. This makes it
Photo #4 Haul-off unit Photo #5: Foam board with cement coating
XPS Physical Characteristics Market size and
Value situation
Property (Metric) (Imperial) Foamed plastic insulation represents
3 3
Typical Densities kg/m (lb/ft ) 30, 33, 35, 1.8, 2.0, 2.2, around 40.6% of the world’s insulation
45, 48 2.8, 3.0 demand according to estimates by The
Dimensions mm (inches) 1220 x 2440, 48 x 96, Freedonia Group, and its participation is
1250 x 600 49 x 24 expected to increase slightly by 2006.
Thermal Resistance
RDm K/W
2
0.75 World Insulation by Material
2
R-value per inch=˚F.ft .h/BTU 5 Foam Plastics 40%
Thickness mm (inches) 20 - 180 3/4 - 4 Mineral Wood 17%
2
Compressive Strength kPa (lb/in ) 200 - 700 15 - 100
Dimensional Stability % 5 (EN1604) 2 (D2126) Other 5%
Coefficient Linear Expansion
mm/(m-K) 0.08
-5
x10 in/(in˚F) 2.0
Max. Use Temperature ˚C (˚F) 75 165
Water Absorption % 0.2 0.2
Reaction to Fire Class E Fiberglass 38%
Flame Spread 5
The demand for foamed plastic insulation
Notes:
- Extruded polystyrene insulation is made according to ASTM C 578 standards or equivalent in the European has been estimated to show around 5%
system, which require certain minimum densities. annual average growth rate for the next
- Values presented in this table are based on typical properties reported by BASF and Dow Chemical Company.
- Most of the values are for foam boards 50 mm or 2" thick. three years.

The advantages of the cement-reinforced Depending on the final application, The Freedonia’s forecast for this sector is
foam boards are: commercial products are offered with growth around 44% from 2001 to 2006
• Waterproof. different edge or surface finishing to and then around 40% from 2006 to 2011
• Lightweight: 8 lbs (3.6 kg) for a 3’ by 5’ facilitate installation. Some of the options in the Asia/Pacific region. This means an
(.91 x 1.52 m) sheet versus 45 lbs. are: (See Photo #6 on the next page) average annual growth rate of
(20.45 kg) for a traditional cement • Square Edge approximately 6.5 - 7.5%. The participation
backboard.
• Ship-lap of the Asia/Pacific region in the total world
• Easy to install and cut.
• Tongue & Groove foamed plastic insulation demand shows
• Keep tiles warm by reducing the heat
• Grooved Surface (for drainage)
loss through them.
• Improves sound insulation. • Embossed surface World Foamed Plastic
Insulation Demand by
XPS vs Fiberglass Batts Region 2006 (million US$)
XPS Fiberglass Batts
Superior moisture resistance No complete support for wall systems
Ensures long term insulation in wet No complete insulation of wood frame Asia/Pacific N. America
environments (2275) 30% (2375) 32%
Excellent dimensional stability Thermal bridging through wood framing
Lower condensation potential Different options as face material:
Kraft paper, foil or plastic film
Africa/
Typical thickness for wall Typical thickness for wall (2100) 28%
Mideast
insulation 1 or 1.5" (25 or 38 mm) insulation 3.5" (89 mm)
W. Europe
(270) 4%
Non-toxic Depend on framing for support Latin
E. Europe America
R-value per inch = 5 R-value per inch = 3 - 3.5 (210) 3% (240) 3%
an increase of 4% from 2006 to 2011 at
the expense of some reduction (around World Foamed Plastic Insulation Demand 1996 - 2011
2%) in North America and Western Europe. 9490
10000
The North American market for foam 7470
plastic insulation was estimated in 1.9 8000
5834
billion dollars and growing to 2.37 billion 5449

million US$
6000
by 2006 or around 3.5% annual average
growth rate. 4000

CMAI however has estimated a reduction 2000

on the consumption of PS in the building
and construction market for 2002 to 2003 0
1996 2001 2006 2011
with a negative growth rate of -5% in USA
and Canada. Total demand of PS for this
U.S.A. & Canada - PS Demand for Building & Construction
market sector is forecasted to reach 344
million lbs. (156,300 Tons). The situation
(excluding EPS)
looks a little better for 2004 with an
400 362
estimated 2% annual growth rate over 351
350 344
2003 consumption, reaching 351 million
300
million lbs.

lbs. (159,500 Tons).

250
The European situation for EPS demand 200
for the construction sector, according to 150
CMAI, showed a reduction in its growth 100
rate of -18% from 2002 to 2003, but is 50
expected to grow 15% for 2004.
0
2002 2003 2004
The market for insulation material is mainly
driven by the building and construction
industry. Due to a recession in the year
W. Europe PS in Block Demand for Construction
2001 and for the beginning of the year 605
600 572
2002, the housing starts decreased in
497
thousand metric tons

Western Europe by –6% in 2001 and were 500

estimated to decrease another –1.2% in
400
2002. For the year 2003, the forecast
sees a positive development with a small 300
growth rate from 0.8%. 200

The European market for XSP has been 100

estimated by IAL consultants to be 4.3 0
3 3 2002 2003 2004
million m (151.9 million ft ) in 2003 with
98% of it being dedicated to building and
construction, and just 2% to the industrial Conclusions
sector.
Building and construction are the main markets for
insulation foam boards. Although this product competes
with fiberglass and other insulation materials, the ease
of manipulation and installation give foam boards an
advantage over the more traditional options. Future
trends for foam boards are seen as:
• More productive and efficient equipment
• Increased popularity
• New applications
German Laverde
Director of Marketing
and Communications
Photo #6: Foam board edge finishing treatments

History of Plastics
In today’s world, life without plastics is incomprehensible.
We all know the many ways that plastics contribute to
our health, safety and peace of mind. But how did the
material plastic come about? Who were the key
individuals in its development and use? In each Tech
Liner issue we feature one element of plastic’s amazing
history.
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The Discovery of Cellophane
Cellophane was discovered by Dr. Jacques Edwin
Brandenberger, a Swiss textile engineer, who came upon the
idea for a clear, protective, packaging layer in 1900.
Brandenberger was seated at a restaurant when he noticed a
customer spill a bottle of wine onto the tablecloth. The waiter
removed the cloth replacing it with another and disposed of
the soiled one. Brandenberger swore that he would discover
someway to apply a clear flexible film to cloth, which would
keep it safe from such accidents and allow it to be easily
cleaned with the swipe of a clean towel.
He worked on resolving this problem by utilizing different
materials until he hit pay dirt in 1913 by adding Viscose (now
known as Rayon). Brandenberger sprayed liquid viscose on
cloth, but the end result was a brittle material that was too stiff
to be of any use. However, Brandenberger noted that the
coating peeled off in transparent sheets, and saw other
potential uses for the viscose material. He developed a new
machine that could produce transparent viscose sheets, which
he marketed as Cellophane. With a few more improvements,
Cellophane allowed for a clear layer of packaging for any
product -- the first fully flexible, waterproof wrap.
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U.S. Postage
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