Expanded Polystyrene (EPS)
EPS is a light weight, completely recyclable material that has various applications in packaging and insulation. It can be moulded to virtually any shape, giving unlimited freedom to designers. Here, at K. K. Nag Ltd, we cater to a variety of customer sectors that include white goods, FMCG (Fast Moving Consumer Goods), pharmaceuticals, agricultural products, the automobile industry, construction, electronics and fisheries.
Annually, we process approximately 4,500 tonnes of EPS from our 4 factories, making us one of the largest EPS shape moulders in India. Our units are spread across the country in Maharashtra (Urse and Ranjangaon), Tamil Nadu (Thiruvallur) and Puducherry and we have more than 50 machines that range from 400×600 mm to 1300×1700 mm in platen size. We are proud to say that we are reputed to be the most technically progressive and competent EPS processor in India.
Everything, from conceptualisation to the final product, is handled by our expert in-house team. This includes prototyping and design, development and manufacture of EPS moulds and the moulded parts.
We were the first EPS processor in India to receive ISO 9001:2000 certification and have since been certified for ISO 9001:2008, ISO 14001:2004, BS OHSAS 18001:2007 and ISO/TS 16949:2009. K. K. Nag Ltd is also the single source EPS supplier to several renowned national and international brands.
Applications of EPS
EPS Used in photo frame moulding. EPS is one of the most cost-effective protective packaging materials available and is used all over the world to protect goods from transit damage. It possesses an extraordinary combination of lightness, rigidity and shock absorption and can be moulded to virtually any shape desired.
EPS is also used widely for low temperature thermal insulation because of its low thermal conductivity and closed cell structure (most other thermal insulation materials have open cell structures which make them vulnerable to moisture penetration). Because EPS has no taste or odour and does not harbour fungi, it is used extensively in the packaging of pharmaceutical products, such as vaccines, where stringent temperature ranges are required to be maintained.
EPS is also used to make internal components for the air-conditioning and refrigeration industries. Earlier, these parts were made by gluing insulation materials on to a metal sheet but they have been now replaced by EPS because it possesses both rigidity and the required insulation properties, and can be moulded in one piece.
EPS is now widely used for the packaging of agricultural products in India and various countries. Fruits such as grapes, pomegranates, papayas, mangoes and many others, and various types of vegetables, are conveniently packed and stored in EPS containers. Even in the marine industry, EPS boxes are used extensively to stock fish and other seafood.
Another useful application of EPS is in construction.
Its high thermal insulation makes it an excellent material to use in the construction of walls and ceilings and its high sound absorption makes it the ideal choice for sound-proofing.
Another recent application of EPS is as “Geofoam” in landfills. This application is made possible because of EPS’s light weight, water resistance, dimensional stability and inert nature.
EPS is a relatively modern material (developed in the 50´s)
but is one of our companions in our everyday life and easily
identified among the various plastics materials. The
conversion process into the foam structure is quite simple
and it is called steam moulding. This process goes through
Pre-expansion: in this stage tiny spherical EPS beads are
expanded to 40 times their original size using steam as
Stabilization: the pre-expanded beads are stabilized in
ventilated silos where just air is diffused into the beads.
Moulding: the beads from the silos are conducted to a
moulding machine where the beads bond together, by
means of steam and pressure and the final shape is
This process results on moulds with extraordinary qualities
for the fulfilment of all packaging needs:
Protective: the outstanding shock absorbency and
compression resistance provides excellent protection
Insulation capacity: the thermal insulating properties of
EPS keep food fresh and prevent condensation -
guaranteeing that fish, fruit and vegetables can all be
safely distributed to retain their freshness and their shape.
Durable: EPS remains unaffected by damp, moisture or
heat and its soft surface protects against any damage.
Ligtweight: EPS is 98% air and it is one of the lightest
packaging materials in existence.
Versatilility: Packaging is customized to fit the smallest
component or the largest fridge-freezer. The latest
computer design techniques ensure that packaging is
kept to a minimum yet is 100% fit-for-purpose.
These outstanding qualities make EPS a magic material not
only used for packaging of the most variety of products
but also for other applications from a bicycle helmet to a
And once the EPS packaging has been used then it can be
recycled for various applications.