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The objective of the project is to develop an environment friendly, novel and efficient alternative process for expansion and molding of polymeric foam. Spherical, expandable polymer beads are prepared from liquid monomer suspended in an aqueous medium, containing an expansion agent. The most common expansion agents used are pentane isomers. A major disadvantage of pentane isomers is their high flammability (Flash point –50°C) and volatility. These blowing agents are Volatile Organic Compounds (VOC) and are suspected to be carcinogenic, to be flammable and to contribute to smog. VOC also contribute to the generation of stratospheric ozone. Within the next few years the polymer industries will be forced by new regulations to drastically reduce the level of VOC emission. The current production process of foam uses steam as the energy source for expansion of solid polystyrene beads. The machinery associated with steam generation and transmission takes up a substantial floor space as well as ceiling space in ducting. Multi step process increases maintenance cost and chances of failure. In addition to the gaseous emissions there is also a substantial amount of solid waste generated during the production of EPS using the existing process. The protection of industry human resource and reduction of flammable emissions require expensive plant ventilation and gas collection systems.

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An appropriate approach for reducing the health hazards associated with production of EPS foam is the replacement of the currently used expansion agents. We propose a chemical reagent that is benign, recyclable and susceptible to heating by appropriate electromagnetic radiation. This new process would also lead to a clean, economic and efficient production, drastically reducing raw material cost, cost of maintaining safety standards and reducing shop floor space.

An appropriate approach for reducing the health hazards associated with production of EPS foam is the replacement of the currently used expansion agents. We propose a chemical reagent that is benign, recyclable and susceptible to heating by appropriate electromagnetic radiation. This new process would also lead to a clean, economic and efficient production, drastically reducing raw material cost, cost of maintaining safety standards and reducing shop floor space.

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