Bead Manufacturing

Our raw material is essentially pellets of plastic the size of a grain of sand. These pellets contain a gas which acts as an expanding agent when heated. Using a steam process we heat the pellets which softens the plastic and makes the gas expand. As the plastic undergoes a process of expansion, it increases in size by up to 50 times with the finished product being made up of 98% air.

What is Expanded Polystyrene (EPS)?

It is a lightweight cellular material consisting of fine spherical shaped particles which are comprised of 98% air and 2% polystyrene. Expandable polystyrene is a rigid cellular plastic containing an expansion agent called pentane.


Production Process

Pentane is a liquid that is continually formed in natural processes. For example, it appears in the digestive systems of animals and in the anaerobic decomposition of vegetable matter by micro-organisms.


It belongs to the same chemical family as other better known gases like methane, ethane, propane and butane which are used as heating fuel. Pentane released during the EPS manufacturing process quickly turns into carbon dioxide and water in a photochemical reaction. It does not contain chlorine and so does not harm the ozone layer like CFCs or HCFCs.


Steam is used as energy in the manufacturing of EPS. The steam itself is produced in boilers mainly using natural gas as fuel. Water consumption used in the manufacture of EPS is very low. The water is reused many times in the process. There is no solid waste generated during the EPS manufacturing process. Waste and off-cuts are easily put back into the production process. No material is wasted and clean used packaging can be recycled into new product using this method. There is no pollution to the surface or underground water supplies near an EPS plant because atmospheric and liquid emissions are very low during the manufacture of EPS.

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Benefits of EPS in Construction and Retrofit

Low Thermal Conductivity: the material has a long term R-value meaning it is resistant to heat flow making it an ideal product for thermal insulation.


Lightweight: the lightweight properties of EPS bead makes it easy to transport and allows safe use on site


Low Water Absorption: EPS bead does not absorb moisture and its thermal properties are not affected by damp, humidity or moisture. Its closed cell means it cannot absorb water and bead will maintain its shape, size, structure and appearance.


Ageing Resistance: all the above properties are retained over the materials life and will last as long as the building itself.



Energystore are active members of the leading construction industry associations. Energystore are committed to obtaining and maintaining even more industry accreditation’s and standards to demonstrate our focus on quality assurance. Here are some examples of the certificates, accreditation’s and trade bodies Energystore is associated with:

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