Jun. 17, 2024
EPS (Expanded Polystyrene foam) is one of the most widely used types of plastic. It has become the go-to lightweight solution across various industries, given its low cost. Whether its fast-food packaging, cushioning for your fragile deliveries, or basic insulation, its something you might encounter daily. And thats precisely the problem.
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EPS is by no means an eco-friendly or environmental solution. All EPS leaves its mark. Thats where EPS alternatives come in. Its no wonder that more countries have put a ban on EPS. With consumers and multiple industries taking a stand against polystyrene products, we must continue to explore genuine, sustainable alternatives, wiping out EPS use altogether. To get you started, weve put together a list of the top EPS substitutes, unpacking their pros and cons.
What Is The Ban On EPS?
New York kickstarted January with a ban on expanded Polystyrene foam containers and packing peanuts used for cushioning with online deliveries. Banning single-use plastics is becoming more and more widespread, starting with plastic bags and straws. While dozens of US cities and counties have banned EPS food packaging, peanuts, and coolers, (most are in California) as of today, there are only eight state-level bans in Colorado, Main, Maryland, New York, New Jersey, Vermont, Virginia, and Washington State.
In when the U.S withdrew from the Paris Climate Accord, grassroots organizations sprung into action, doubling their efforts to push conscious consumerism. To date, most cities and states have community-driven advocacy groups pushing for environmental legislation on a local level. You guessed it, one of the products receiving the most attention is EPS, and its no wonder why.
The Pros And Cons of EPS
Before we unpack the pros and cons of EPS substitutes, lets take a moment to understand the ins and outs of EPS itself.
Pros
Expanded Polystyrene provides top-quality lightweight insulation. Thats why its so prevalent in the foodservice industry. You can serve piping hot coffee in a EPS cup, and itll maintain the heat all while preventing your fingers from burning. Better yet, itll keep your to-go food warm or cold until you have the chance to eat it, providing a solution to keep food fresh for longer. EPS is moldable, making it easy to create various containers in all shapes and sizes. On top of that, it weighs less than paper, making it an easy solution for cushioning in packages.
Cons
EPSs impact on the environment is extensive. While many believe its biodegradable or recyclable, EPS is far from eco-friendly. It may break down in high temperatures, but it pollutes our earth with alarming volumes of microplastics, affecting animals and humans alike.
You can recycle only some forms of Polystyrene, but its incredibly costly. Most local recycling plants arent equipped with the right machinery. On top of that, recycled EPS cant be used again in the foodservice industry, defeating the whole purpose of recycling in the first place.
To make matters worse, EPS is made from nonrenewable fossil fuels and synthetic chemicals, all of which contribute to pollution.
Top Five EPS Alternatives
1. Cruz Foam
Pros
Cruz Foam offers an earth-friendly plastic alternative to EPS. The foam is created with naturally-sourced biopolymers. Unlike the synthetic chemicals used in EPS production, biopolymers are sourced from nature while having the same technical properties. The foam is certified compostable, producing bio-benign organic waste with the stamp of approval from USDA Bio-based Preferred.
Cruz Foam offers natural solutions to meet similar technical specifications to legacy materials, offering scalable solutions to various industries. Better yet, Cruz Foam utilizes existing manufacturing equipment and personnel, making the transition seamless on all fronts and creating new green jobs.
Cons
Cruz Foam takes approximately 4 months to fully compost in an industrial compost setting. Although this seems like a lengthy bit of time, its a far cry from many other alternatives or EPS itself, which takes hundreds of years. Plus, Cruz Foam has yielded a 97.9% average biodegradation in soil lab testing, with zero adverse effects on compost quality and produces high-quality fertilizer.
2. PLA Lined Paper
Pros
Polylactic Acid (PLA) lined paper is an excellent sustainable alternative to EPS food packaging. Its a plant-based resin made from corn starch used to create compostable containers and liners for cups or packaging to avoid water damage. Its a solution for hot and cold products, withstanding temperatures between 32 and 185, and you can use it in the microwave or the oven.
Cons
PLA lined paper has poor heat transfer. Unlike a EPS cup which protects your hands from burning, a PLA lined paper cup gets hot, making it difficult to touch without a layer of protection.
3. Edible Packing Peanuts
Pros
While they may not be as tasty as natural peanuts, you can replace EPS packing peanuts with compostable ones made from corn, grain sorghum, and other crops like wheat. They dissolve in water, and you can throw them onto your compost piles after a single-use, leaving zero harmful traces behind. Plus, they have no electrostatic charge meaning they wont stick to your clothing.
Cons
Compostable packing peanuts are heavier than traditional EPS peanuts, meaning theres an inevitable increase in shipping costs. Its also more expensive to produce with crops like corn taking up space that could have otherwise been used for food production. In a challenging economy, its a tricky alternative.
4. Plantable Packaging
Pros
Plantable packaging incorporates seeds allowing consumers to bury the packaging in the soil. Utilizing new technology, its a 100% compostable and plantable product. While it disintegrates, flowers and herbs flourish! All you have to do as a consumer is soak the box in water and then bury it one inch below the surface.
Cons
Plantable packaging cant withstand water, making it an inappropriate foodservice solution. Theres certainly room for it in product packaging, but there are limits when it comes to sizing.
5. Mineral Filled Polypropylene
Pros
Mineral filled polypropylene products (MFFP) contain 50% less plastic than standard polypropylene products, drastically reducing the amount of plastic required. Instead of plastic, its made with mineral content. Its a great solution for hot and cold foods, and its microwaveable, with a temperature tolerance of 240.
Cons
While it reduces the total volume of plastic, it doesnt eliminate it. Thats where it falls short as a long-term solution. On top of that, you cant recycle it, making it a mediocre alternative.
Start Using Alternatives Today!
EPS products are the easy way out. They may be cheaper or lighter, but their overarching impact on the environment is monumental. Thats where the quest for an appropriate alternative becomes a priority. Use this list to kickstart a change that makes a global impact.
Written by Maya Jensen
Foamed polyethylene shells are used for pipe insulation:
Insulation sheet based on polyethylene foam is used to isolate:
Foamed polyethylene bundles are used to seal:
The main factors that pipelines require protection against are:
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Related links:Insulation for pipes made of foamed polyethylene is able to provide effective protection against all these factors.
Low density polyethylene (HDPE) granules are poured into the hopper, where they melt and are evenly mixed. Further, the resulting mass is subjected to foaming with gas or special reagents. At this stage, pigments and modifying additives are introduced into the melt. Then the heated mass is pressed through an extruder to give the insulation to the required shape.
Thermal insulation for polyethylene foam pipes is endowed with numerous advantages:
However, this insulation also has three main disadvantages:
Polyethylene foam does not withstand mechanical stress
Foamed polyethylene (polyethylene foam, PPE) is an insulating material that belongs to foamed plastics. Unlike expanded polystyrene, which is considered by many to be the only foam, PPE remains elastic after polymerization.
As a result, the insulation resembles foam rubber in its consistency and cannot withstand mechanical loads. Because of this, it is used very limitedly for thermal insulation of walls or floors.
The photo shows the cellular structure of the material.
PPE is often used as packaging for furniture.
Polyethylene foam has a closed cell porous structure. This eliminates the saturation of the material with water and the penetration of water vapor through it. This feature has become one of the defining ones when choosing this polymer as a heat insulator for pipes.
Thermal insulation of pipelines is the main area of application of PPE.
The foil coating will protect the insulation from UV and IR radiation.
Foamed polyethylene pipes are easy to install both on the pipeline under construction and on the finished pipeline. This quality, along with low thermal conductivity, safety, chemical inertness and corrosion resistance, determined the popularity of the material, because today PPE is the most popular insulation for pipes.
Installation of polyethylene foam can be done by hand.
The tubing can be simply slid onto the tubing during system assembly.
Consider the technical characteristics of polyethylene foam in order to better understand its features.
To begin with, there are two types of polyethylene:
Non-stitched (top) and stitched (bottom) polyethylene.
When buying material, make sure that you are looking at the sewn PPE. Otherwise, thermal insulation made of foamed polyethylene will be of poor quality, quickly lose its shape and lose its properties.
This is what chemically cross-linked polyethylene looks like in section.
Another example of stitched foam.
This photo shows the structure of uncrosslinked polyethylene.
Specifications:
PropertyUncrosslinked PPEStitched PPEDensity, kg / m³20--200Thermal conductivity coefficient, W / m * K0.038-0.039alsoWater absorption,% by volume0.20.9-1.1Flammability group according to GOST -94G2-G4G1-G4Vapor permeability coefficient, mg / m * h * Pa0.001alsoHeat capacity, W / m * ̊ 1.8alsoGroup by the ability to smoke in accordance with GOST 12.1.044-89D3alsoDurabilityat least 25 years80-100 years oldAbility to keep in shapelow, mediumhigh
XLPE is more expensive than uncrosslinked polyethylene
From the characteristics it can be seen that the material belongs to high-performance heaters with a low coefficient of thermal conductivity. Cross-linked PPE is better suited for pipe insulation, although its price is noticeably higher. Nonetheless, crosslinked PES remains the most advantageous for this purpose.
The inner diameter of the insulation must be the same as the outer diameter of the pipe.
Benefits:
The temperature range that polyethylene can withstand is -60 to +90 ° C
Combined use of PPE with a heating cable is allowed.
Disadvantages:
Like any plastic, PPE burns well.
Products for pipe thermal insulation must have:
To understand the features of foamed polyethylene, you should study the technical characteristics of this insulation, it is produced in two types:
The first type is a polymer, the molecules of which do not have additional bonds in space, due to which the material has less elasticity, strength and density, when compressed, a characteristic crackle is heard and the original shape is lost.
The second type is obtained by a chemical or radiation method, that is, under a specific external influence, not only linear, but also cross-links or in other words "crosslinking" are formed between the PES molecules, that is, the material turns out to be dense, strong and elastic, and after its compression the initial shape quickly is recovering. Therefore, in order for polyethylene foam pipe insulation to be of high quality and effective, it is better to give preference to products belonging to the second group.
Main technical characteristics of crosslinked insulating material:
Thermal insulation materials made of polyethylene foam are divided into types according to several criteria:
The rolls have a width of 60 to 120 cm, a length of 2 to 30 meters, the sheet thickness in them is no more than 5 cm. Tubes are produced in lengths from 1 to 10 meters with a wall thickness of 632 mm and a diameter of 6 to 160 mm.
Crosslinked polyethylene foam is called, the structure of which is modified at the molecular level under the influence of external factors. The result is a material with very small, closed cells that is more resistant to stress.
There are two types of cross-linked polyethylene foam:
The cross-linked polyethylene pipe insulation is more durable, elastic and dense. It has a shape memory effect for insulated structures.
Uncrosslinked polyethylene foam is designated by the letters NPE. Formed in the process of processing polyethylene with gaseous reagents (a mixture of propane-butane or freon). This type of insulation has a structure with larger gas-filled cells.
Foamed polyethylene pipes, which have a technical slot along their entire length, can be easily put on already installed lines. To install them, you do not need to dismantle pipe sections. The edges of the halves are joined end-to-end and glued with metallized tape.
The thermal insulation material is in the form of hollow cylinders with a solid surface. They are installed on the pipe during the pipeline assembly process.
The material is coated on one or both sides with a thin layer of aluminum foil or metallized film. The maximum adhesion of the layers is achieved by thermal welding. To increase the heat-reflecting effect, the foil is polished. Foil insulation made of foamed polyethylene has:
Foam polymers are divided by types of manufacture, on which the quality and price of products depend:
Uncrosslinked polyethylene foamIt is made of budget material, so its price is lower. It is used for laying insulation layers or packaging electrical equipment. It is rarely used for other purposes.Chemically crosslinked polyethylene foamTo create this type of material, chemicals are used. additives (most often hydrogen peroxide or other catalysts). As a result, polyethylene is obtained several times better and denser than non-crosslinked polyethylene.Physically cross-linked polyethylene foamFor production, solid-state electron emitters are used. Radioactive substances are located around the polymer raw materials and pierce microscopic holes with electrons. The density of the material in this way becomes as high as possible. This type of product is excellent for the production of tubeshell, creating a protective layer around the pipe, but it does not cope well with thermal insulation. This is the most expensive type of polyethylene foam.We recommend that you familiarize yourself with: Purpose and application of wafer-type check valves
I have heard many positive reviews about heaters Vilatherm, Isolon, Penoline, Merilon, EnergoFlex and Thermaflex.
Vilatherm is produced by a Moscow company. The material has a fine-mesh structure with closed pores, is hygroscopic, absorbs shock and noise, and is environmentally friendly. Due to the high air content, it has high thermal insulation properties.
The assortment consists of harnesses and cylinders. Insulation in a cylindrical shape is suitable for insulating pipes both in new, installed objects, and for existing, operated pipelines.
OJSC Izhevsk Plastics Plant produces two types of sheet insulation with a thickness of 1 to 5 cm under the Izolon trademark:
Isolon has a very low heat conductivity coefficient. It reliably protects the room from steam and moisture.
Heat-insulating mats and pipe insulation Penolin are produced by CJSC Information Technologies Plant LIT. It is available in various thicknesses and colors, the width of the blade is 110 and 125mm. It is possible to cover the insulation with aluminum foil, plastic metallized film and other materials.
Insulation pipe MERILON (Czech Republic) is produced with an inner diameter of 15 to 110 mm and a wall thickness of 6 to 18 mm, which causes a different degree of insulation. Foamed polyethylene Merilon has an extremely porous structure.
It is moisture-proof, not subject to decay. The structure with many air cells provides it with good thermal insulation properties.
Energoflex is an environmentally friendly polyethylene foam insulation that meets all European standards in quality. Freon is used for its manufacture, so the material resists the diffusion of water vapor better.
It is used to protect various pipes, containers and fittings from heat loss. Thermal insulation is produced in the form of sheets, rolls and sleeves of various diameters.
(Netherlands) produces a wide range of pipe and sheet heaters for engineering systems operating in the temperature range from -80 to +110 ° C. Thermoflex has low thermal conductivity and high resistance to water vapor diffusion, retains good elasticity at subzero temperatures, does not absorb moisture and does not decompose.
When choosing a polyethylene foam insulation, consider the following factors:
Average prices from different manufacturers are:
When choosing thermal insulation, the location of the pipes, the density of the material and its size are taken into account:
Note! In places where pipes are located on the surface under the rays of the sun, polyethylene foam with a protective polymer layer is used.
One of the important parameters when choosing is the size of the cells of the material. The smaller the size, the greater its ability to retain heat:
We recommend that you familiarize yourself with: Pros and cons of one-pipe and two-pipe heating systems - which is better and more efficient?
AppointmentThe sizeinsulation for cold water pipes9 mminsulation for heating and hot water systems13-20 mmscreed pipes or in walls6 mmThere are several general rules that must be followed when installing foam insulation:
For thermal insulation of the door leaf, it is enough to cut a blank from a sheet of polyethylene foam by measure and fix it on top with a finishing material. On the surface of the enclosing structures from the inside of the house, foamed thermal insulation can be laid under drywall, which will significantly reduce heat loss.
It is better to insulate the balcony or loggia with polyethylene foam with a protective film from ultraviolet radiation or foil material. It will reliably protect these structures from moisture and street noise, while their area will decrease slightly.
Polyethylene foam insulation is a huge range of materials that differ in thickness, dimensions and the presence of auxiliary protective coatings. Their scope is not limited only to the insulation of communication wiring:
The installation of pipe insulation is often performed after the assembly of the pipeline. It is impossible to put on one-piece cylinders on the mounted sections of the pipeline, therefore, products with ready-made cuts are used or cut during installation. The edges of the cut sleeves are fixed with special tape after installation on the pipes.
Installation should begin with surface preparation of the pipes:
I usually glue the outer pipe insulation along the cuts and at the joints. If the pipes are inside the building, then it is not necessary to glue the insulation along the entire length. You can simply fix it with one tape.
Features of installing thermal insulation in places of pipe branching, see the video.
If you need to insulate the walls of the house from the inside, then you need to measure their width and height in all rooms. Then multiply these parameters to calculate the area of each wall separately, and sum the values obtained to determine the total area of insulation. Further, from the amount received, you need to subtract the area of the window and door openings in order to determine the required amount of thermal insulation material.
Pipe insulation is calculated even easier - according to the total length of the pipelines to be insulated.
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