NexKemia Petrochemicals, a specialist in expandable polystyrene (EPS) production, is expanding its manufacturing capabilities using Coperion’s ZSK twin screw extruder technology. The system enables continuous, energy-efficient, and environmentally friendly production of white and graphite-enhanced EPS (GPS), as well as products containing up to 30% recycled material.

Traditionally, EPS has been produced through batch-based suspension polymerization, a process requiring tight chemical control. Coperion’s ZSK twin screw extruder simplifies this with a single-step, continuous manufacturing process. All raw materials are precisely dosed via Coperion K-Tron feeders and homogeneously mixed in the extruder with minimal shear and short residence time, ensuring gentle handling and consistent quality. The resulting micropellets, produced via underwater pelletization, feature a narrow particle size distribution and superior material performance.

Beyond simplifying production, the ZSK extruder enables the seamless integration of recycled content. Cleaned and compacted regrind can be directly reintroduced into the process without compromising quality, supporting circular economy goals. Compared with conventional methods, the process produces significantly fewer airborne emissions and less wastewater, enhancing both sustainability and cost-efficiency.

“NexKemia and Coperion have worked closely to create new, sustainable processes for EPS production,” said Michael Hays, President of Integreon, NexKemia’s parent company. “This collaboration allows us to innovate responsibly while delivering high-performance, eco-friendly insulation and packaging materials.”

Focusing on innovative manufacturing processes and sustainability, NexKemia provides products for the packaging industry and as well as for building insulation: white EPS, EPS mixed with graphite, as well as products containing up to 30% recyclate.

With the Coperion ZSK twin screw extruder efficient production of EPS microbeads is possible on a single machine.