From Bead to Block: The Journey of Expanded Polystyrene (EPS) at KORE Insulation
At KORE Insulation, innovation, efficiency, and sustainability go hand-in-hand. With Expanded Polystyrene at the heart of what we do, it is one of the unsung heroes of modern construction. The EPS starts life as a tiny bead and transforms into a high-performance insulation.
Here’s how we make that happen.
1. Raw Material
It all begins with polystyrene beads, delivered in large Octobins each holding just over 1,000kg. These small beads are engineered to expand dramatically. Though tiny, they hold the key to producing a material that’s strong, lightweight, and thermally efficient.
2. Expansion
Next, we use steam to expand the beads up to 30 to 40 times their original size. This stage transforms dense plastic granules into lightweight, air-filled spheres making EPS around 98% air and incredibly resource-efficient. no chemicals are used in this process.
3. Silo Rest
Post-expansion, the beads are stored in silos to stabilise and breathe. This rest period is essential to ensuring consistency in density and performance when it’s time to mould the blocks.
4. Moulding
The beads are then transferred into block moulds, where they’re steamed again to fuse into solid EPS blocks. This is where we can integrate regrind from offcuts, supporting our goal of reducing waste and promoting a circular production model.
5. Cutting
Once cured, the EPS blocks are precisely cut into a range of sizes and shapes to suit project needs whether it’s for the likes of external wall insulation, floor insulation, or roofing applications.
6. Quality Checked
Every product undergoes strict quality control to ensure it meets our performance and safety standards. From thermal performance to compressive strength, consistency is non-negotiable.
7. Delivery
Finally, our finished EPS insulation products are packaged and delivered to site.
This leaves us with a product that is lightweight yet durable, EPS is easy to handle, efficient to transport, and ready to support energy-efficient construction across Ireland, NI and the UK.
Why this Process Matters
EPS isn’t just about insulation it’s about performance, sustainability, and Innovation. With low embodied carbon, excellent thermal performance, and 100% recyclability, EPS plays a key role in meeting modern building standards, including NZEB and Passive House.
At KORE, we’re proud to deliver insulation that’s built by a culture of continuous learning & development and staying true to the processes and innovations that got us here.
