JULY - 20219MANUFACTURING TECHNOLOGY INSIGHTSprotection in the event of a vehicle crash. They are also being increasingly used in areas such as seating and trunk storage and stowage applications. As the automotive industry moves toward increasingly stringent efficiency standards, and as the industry transitions to electric vehicles, EPP foams are being used to achieve vehicle weight reduction, thus allowing OEMs to achieve efficiency and range goals. EPP foam can be optimized to achieve specific weight reduction targets while maintaining product performance. Figure 1 illustrates various applications where EPP foams are used in vehicles.The benefits of Polyolefin foams like EPP are their durability, chemical resistance, repetitive impact performance, and broad operating temperature range (-30°C to 110°C). EPP products are completely inert and produced without the use of VOCs. They are also 100 percent recyclable. With more emphasis on End-Of-Life vehicle disposal and recycling, it is important to consider the selection of products being used for vehicle interiors. Single component materials like EPP facilitate ease of disassembly and recycling. EPP can be recycled as a number 5 plastic (>5< recycling code). Another growing field with a great potential for durable foamed products like EPP is the packaging and food service industries. With the growing emphasis on recyclability, there is a growing concern with current plastic collection systems at the municipal level to cope with the number of different types and forms of plastics. As such, there is a renewed interest in reusability. This is an area where EPP foam products offer great benefits. EPP foam products, due to the inherent durability and insulation properties, can be reused multiple times, are resistant to chemicals, and can be cleaned and disinfected. Areas of opportunity include home delivery of appliances and groceries, on-site store pick-up of food items (perishable, hot, cold, etc.) with an emphasis on long-term use and reuse, with the ability to clean and disinfect between uses. EPP foam offers a lightweight solution to replace solid plastic containers with the added benefit of maintaining both hot and cold/frozen products in the same container for extended times, without secondary packaging or ice packs. This concept is also being used to transport assembly components for the automotive, appliance, and other manufacturing markets, whereby EPP is used for durable, reusable transport totes. Figure 2 illustrates multiple designs and uses for EPP packaging.An added benefit is the end-of-life (which can be up to 5 years or more) recyclability and established recycling networks that take back EPP foam containers. Once these EPP parts are returned to recycling centers, they can be ground up, pelletized, and used to produce new EPP products. EPP products are currently available with recycled (PCR ­ Post Consumer Recyclate) content of 25 percent or more.Polyolefin foam technology continues to innovate and adapt to a changing marketplace. While the market opportunities are growing, production methods are improving, and manufacturing costs are being reduced. EPP (and EPE) foam products can be used to replace PU (polyurethane,) and PS based foams while offering the combined benefits of cost reduction, weight reduction, chemical resistance, insulation properties, improved durability and longevity, all while being fully recyclable and melt-processable back to the base resin level. FIGURE 2EPP foam products, due to the inherent durability and insulation properties, can be reused multiple times, are resistant to chemicals, and can be cleaned and disinfected
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