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This Case Study intends to enlighten what it takes to meet the challenges towards becoming a quality manufacturer of EPS. The future of EPS production is focused on EPS moulded products of low heat transfer low lambda value or high R-value and conventional white EPS with low pentane and still with fast expansion properties.
While EPS of bead sizes between 0,4 — 1,8 mm diameter was in market demand from the conventional 1-step polymerization processes, the increasing demand for low lambda EPS grey EPS will require the bead size range of 0,,8 mm diameter block moulding, and low pentane EPS white EPS will require the bead size range of 0,,0 mm diameter.
EPS outside these bead size ranges must substantially be re-defined as off-specification materials. So therefore, it takes a team of highly qualified scientists to develop new reactor processes that meet demand for new EPS products.
Narrow bead size distribution and mean bead size control represent the basis for being able to produce prime EPS products only, which can be accomplished by extraordinary suspension stability. Requirement for an open pressure less reactor polymerization system with sampling procedures are the first signs of un-stable suspension. A closed reactor is the pre-requisite to reach adequate production safety of low emission standards. In-adequate suspension stability reduces productivity and increases opportunity losses through regular production stops and output of lower value added products.
Utilization of a high plant capacity represents a main factor for consistent earnings. In a narrow bead size production output of few size fractions will simplify the down- stream process, and thereby reduce energy consumption and maintenance cost, and substantially reduce grade selection and output of off-specification products, and thereby increase output of higher value added prime EPS products.
Profitability is an indirect result of production cost, which accordingly a result of following main factors to be brought under control:. As sale of plant capacity is a main factor for profitability the products must be of high quality and competitive in an international market. Recently, a leading mall in the emirate of Abu Dhabi was facing issues with their cooling system which […].
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