Jun. 23, 2025
Machinery
Looking for the perfect insulation material for your project? Using SOPRA XPS comes with many benefits. This product range performs excellently in terms of compressive strength, reliability, durability, climate-friendliness, and recyclability – among other characteristics. In what follows, we explain the advantages and disadvantages of XPS insulation in more detail.
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Our insulation boards have excellent load-bearing capacities, making them the ideal choice for – among other applications – ballasted roofs, rooftop car parks, parking garages, floors of industrial buildings that have to bear the weight of heavy machines, and cold storage environments where both compressive strength and insulation performance are required. SOPRA XPS 500 and SOPRA XPS 700 perform well under high compression, with respective compressive strengths at 10% deformation of 500 and 700 kPa.
SOPRA XPS provides good thermal insulation even in boards with limited thickness. Our XPS boards with 300 kPa start from 30 millimetres; 500 kPa from 40 millimetres; and 700 kPa from 50 millimetres. The maximum thickness is 300 millimetres, depending on the panel. SOPRA XPS CW Artic and SOPRA XPS SL Artic go up to 200 millimetres in thickness.
The closed-cell structure of XPS results in very low lambda values (ranging from 0.029 (for SOPRA XPS Artic) to 0.036 W/mK).
Soprema offers a forty-year SOPRACOVER Warranty on systems consisting of SOPRA XPS and DUOFLEX – a combination that is frequently used in inverted roofs, plazas and podiums. As this impressive warranty already makes clear: provided installation and maintenance instructions are followed, XPS boards have a very long lifespan and will not degrade over time.
XPS insulation is highly resistant to water and moisture ingress due to its closed-cell structure, making it the go-to insulation material for foundation walls and other below-ground applications, as well as for inverted roofs.
Because XPS boards are very light and easy to handle, they are easy to install. XPS is the ideal solution for blue roofs and green roofs which require insulation properties and a highly compressive insulant. It can be combined with DUOFLEX where the BBA states approval for blue and green roof applications.
Thanks to its long lifespan, XPS is a more sustainable insulation option than insulation materials that need regular replacement and thus generate waste across the raw material, manufacturing and disposal cycle. But there are more ways in which our BREEAM A-rated SOPRA XPS products prove that plastics in construction can be sustainable.
While our Artic products are manufactured elsewhere, most SOPRA XPS boards are made in Tongeren with climate-friendly CO2 technology. In our Belgian XPS factory, we refrain from using chemicals like HFC and opt for CO2 as a blowing agent instead. Moreover, for raw materials we use the cutting waste of other XPS boards and new or end-of-life EPS, among other resources.
Of course, the fact that XPS insulation enhances the thermal performance of a building (thereby reducing its energy demand), also contributes to its sustainable character.
SOPRA XPS is approved by the Green Guide to Specification.
After disassembly, XPS boards can be 100% recycled. It goes without saying that the extruded boards are a clever move towards a circular economy and a circular construction industry.
XPS has an impressive application versatility. The insulation type is best suited for inverted roofs but has plenty of other applications as well – from floors to walls. For distributors, having one type of XPS panel at their disposal offers a wider scope as the product can serve multiple purposes. The boards also come with various edge profiles, from tongue and groove to rebate and straight.
We have already mentioned that SOPRA XPS and DUOFLEX are often used together, but our extruded boards are compatible with the entire Soprema waterproofing range. Because we manufacture all system components, we can also ensure the product compatibility of XPS with, for instance, basement waterproofing or structural waterproofing systems. Partnering with a single manufacturer for both insulation and waterproofing also results in a single point of warranty and contact.
Fire classification is a disadvantage of some insulation types. XPS insulation has a Euroclass E rating. Yet when XPS insulation boards are used in an inverted roof scenario, with a ballasted finish, the system can be classified as unrestricted in the UK, meaning that it can be used within any distance to other buildings. Similarly, while some cassette-packaged green roof systems will require independent BROOF(t4) testing, a fire test is not necessary to comply with UK guidelines in the case of:
XPS (Extruded Polystyrene) insulation foam is a high-performance material widely used in construction, refrigeration, and other industries due to its excellent thermal insulation properties, moisture resistance, and overall durability. This article explores the production process of XPS insulation foam, emphasizing the technological advancements behind its manufacturing, as well as the advantages of using this material in various applications. Additionally, we'll highlight Feininger's role as a leading XPS foam manufacturer, showcasing its state-of-the-art production line.
XPS insulation foam is an extruded material made from polystyrene, a type of plastic. It is produced by heating and expanding the raw material in a controlled environment, resulting in a dense, closed-cell structure that provides superior insulation. XPS foam is known for its high thermal resistance (low thermal conductivity), moisture resistance, compressive strength, and light weight, making it an ideal choice for a variety of applications, including:
Building Insulation: Walls, roofs, and floors in residential and commercial buildings.
Refrigeration: Insulation for cold storage units and refrigeration systems.
Packaging: Protective packaging for delicate items.
The closed-cell structure of XPS insulation foam also helps to reduce heat loss and prevents the absorption of water, thus extending the lifespan of buildings and products insulated with XPS.
The production of XPS foam starts with the key raw material: polystyrene beads, which are often combined with blowing agents to create foam. Other additives like colorants, stabilizers, and flame retardants may also be included, depending on the application. These materials are carefully chosen to ensure that the final foam exhibits the desired properties such as high thermal insulation, durability, and moisture resistance.
Blowing agents, such as CO2 or pentane, are critical in the extrusion process as they help expand the foam, contributing to its closed-cell structure and improving its insulation capabilities. The combination of these materials is key to producing high-quality XPS foam boards.
The first step in the production of XPS insulation foam is pre-expansion. In this process, small polystyrene beads are expanded using steam, heat, and the blowing agent. This expansion gives the beads a cellular structure, increasing their volume and creating a foam-like texture. The pre-expanded beads are then collected and stored before the next step.
For more information, please visit XPS foam insulation production.
Further reading:Next, the pre-expanded polystyrene beads are fed into an extruder, a large machine that applies heat and pressure to melt the beads into a uniform, molten mixture. The molten material is then forced through a die, where it cools and solidifies into sheets of foam. The blowing agent plays a crucial role in this step by expanding the molten mixture as it passes through the die, creating the foam's cellular structure.
The extrusion process ensures that the XPS foam is consistently shaped and molded to the required dimensions. The foam is then cooled and solidified to maintain its rigid structure, making it suitable for cutting into sheets.
Once the foam has been extruded, it passes through a cooling chamber, where it is allowed to cool and solidify. After cooling, the foam sheets are cut to the desired length and size using precision cutting systems. These cutting systems ensure that the foam sheets are consistent in size and meet the required specifications.
Finally, some manufacturers apply a surface treatment to the foam boards. This can include a coating or lamination process to enhance the foam's durability, increase UV resistance, and improve its overall performance in various environments. Surface treatments may also provide a smoother finish, making the foam easier to handle and install in construction applications.
Feininger is a leading manufacturer of high-quality XPS insulation foam, known for its advanced production lines that utilize cutting-edge technology to produce superior foam boards. Their XPS foam board production line integrates the latest advancements in extrusion and molding technology to ensure consistent quality, efficient production, and high performance.
Energy-efficient Extrusion Technology: Feininger's production line features energy-efficient extruders that maintain precise temperature control. This results in foam boards with a consistent thickness and excellent insulation properties.
Customized Production Capabilities: Feininger offers flexibility in its production line, allowing for customized foam board sizes and densities to meet specific customer needs. Whether for building insulation or industrial applications, Feininger can tailor the product to ensure optimal performance.
High-precision Cutting Systems: Feininger employs automated cutting systems that ensure precise, clean edges on every foam board, enhancing the quality and consistency of the final product.
Environmental Sustainability: Feininger's production line incorporates eco-friendly practices, using non-toxic, environmentally friendly blowing agents. This not only meets industry regulations but also aligns with global sustainability trends.
The quality of XPS insulation foam is critical to its performance, and rigorous quality control procedures are necessary throughout the production process. Feininger, for example, conducts comprehensive tests on each batch of foam to ensure it meets international quality standards.
Common tests include:
Thermal conductivity tests to measure the foam's insulation properties.
Compressive strength tests to ensure the foam can withstand pressure without deforming.
Moisture resistance tests to ensure the foam does not absorb water, which could compromise its performance.
By adhering to strict quality control measures, Feininger ensures that its XPS foam products provide long-lasting performance and reliability.
XPS insulation foam offers numerous benefits for construction and other industries:
High Thermal Insulation Properties: XPS foam has a low thermal conductivity, making it an excellent material for reducing energy consumption in buildings by providing effective thermal insulation.
Moisture Resistance: The closed-cell structure of XPS foam prevents water absorption, which can lead to mold growth or degradation of other building materials. This is especially important in areas with high humidity or water exposure.
Durability: XPS foam is highly durable and resistant to compression, ensuring it maintains its insulating properties for years.
Lightweight and Easy to Install: XPS foam boards are lightweight, making them easy to handle and install in various applications.
Feininger has established itself as a leading manufacturer of XPS insulation foam. With decades of experience and cutting-edge production lines, Feininger is a trusted supplier for businesses in need of high-quality foam insulation products. The company's commitment to quality, sustainability, and innovation makes it a preferred choice for construction and industrial projects worldwide.
Feininger's advanced XPS foam board production line and its dedication to customer satisfaction ensure that it continues to lead the industry in providing reliable, energy-efficient insulation solutions.
The production of XPS insulation foam is a sophisticated process that requires precision, advanced technology, and strict quality control. From raw materials to the final product, every step in the production process contributes to the foam's superior thermal insulation properties, moisture resistance, and overall durability. With Feininger's state-of-the-art production lines, businesses can rely on high-quality XPS foam that meets the demands of modern construction and industrial applications.
For more information or to request a quote for XPS insulation foam products, contact Feininger today to discover how their solutions can enhance your projects.
If you want to learn more, please visit our website XPS foam board machinery.
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