Customized EPP Packaging Foam For Protecting HANWELL

what is epp?

Expanded polypropylene (EPP) is a versatile closed cell beaded foam with a unique set of properties including excellent energy absorption, multiple impact resistance, thermal insulation, buoyancy, water and chemical resistance, extremely high strength to weight ratio, and 100% recyclability.

Epp has a wide range of densities from 15 grams per liter to 200 grams per liter, transformed by molding to 18 grams per liter to 260 grams per liter density. Individual beads are fused into the final product form through an autoclave molding process, resulting in a strong, lightweight shape.

How to process EPP?

The manufacturing process is complex and requires technical expertise and specialized, custom-built equipment. In a multi-step proprietary process, polypropylene resin is combined with other components. Under tightly controlled conditions, the extruded pellets expand to become uniformly shaped expanded polypropylene beads. Other specialized manufacturing techniques can be employed to produce variations in the final product form.

The EPP foam beads are then injected into the mold. In many cases, cost effective multi-cavity aluminum molds are used. Pressure and steam heating melts the beads into the finished shape. The finished EPP foam part becomes a key component of the sub-assembly in the OEM's product.

Weihai Hanwell New Material Co.,LTD was established in 2020, as a member of Han Well Group with Qingdao Hanwell Hightech Plastic Co.,Ltd. With the 20 years development, now the factories cover an area of 100,000 square meters and the workshop is about 80,000 square meters, 50 production lines, the total investment is more than US dollars 50,000,000.

From the EPP raw material, EPP forming products, molded pulp products, therm forming products, plastic slip sheet, we have realized the industrial chain highly vertically integrated in every these industries. Meantime we have a lot of advanced machines from Germany, that improve the quality, reduce the cost, so we can provide competitive price and ensure the big order delivery on time.

With experience on working with the world-class customers from all over the world in the past years, our teams deal with a lot of important cases, our engineer team can help design per customers’ request. Besides this, our aim is to provide the comprehensive solution and help to achieve the constant development together.

As a responsible manufacturer, we work hard on developing new biodegradable and reused packaging, we always improve technology and reduce the energy consumption to achieve the goal of the carbon neutrality and protect our world. If you have packaging request, welcome to contact us, we will be very glad to help you.

EPP is a polypropylene foam consisting of expanded, mainly closed-cell foam particles. The EPP beads are filled with air and therefore particularly environmentally friendly(light weight). They guarantee a good joint tightness of the moulded parts and provide an excellent insulation and thermal insulation.

A high energy absorption（shock resistance）capacity combined with a very good recovery behaviour are characteristic properties of EPP in addition to the good chemical and temperature resistance. The low water absorption( water proof) due to the closed-cell structure and hydrophobic surface property, the easy cleaning of moulded parts, the good thermal insulation capacity as well as its environmental compatibility (= free of propellants and other chemical blowing agents) round off the property profile of EPP.

For the use as reusable packaging and reusable transport and insulation containers, the excellent material properties of EPP are used in an ideal form.

Processing

EPP is processed on automatic foaming machines which are designed for a steam chamber pressure of at least 5 bar. The foam particles are transported from a pressurized container via injectors into the mould. Since EPP does not contain any blowing agent, it is necessary to compress the foam particles in the mould. Welding of the EPP beads to a molded part is done by using water vapor as heat transfer medium. The demoulding is done by mechanical ejectors and/or compressed air. For dimensional stabilization, the molded parts must be tempered (= dried) at approx. 80°C after demolding.

Application areas

The specific product properties of EPP are innovative and unrivalled and make EPP a multifunctional material with almost unlimited design possibilities for a wide range of applications.

EPP proves itself in areas where strength at low weight, high stiffness or good thermal properties are required, such as

• Automobiles as energy-absorbing foam such as bumpers, side impact protection or for sun visors or neck supports
• As protective and reusable packaging for sensitive products
• Electronic engineering as well as heating, air conditioning and sanitary engineering as a multifunctional part with multiple uses (impact protection, thermal insulation)
• In safety relevant products such as child seats and bicycle helmets
• The toy industry or the design and furniture sector
• For the transport of temperature-sensitive foodstuffs from A to B