Plants and services

The production process

A highly technical production process

The machinery that makes up the Emmedue plant provide innovative, efficient and advanced production solutions that assure the creation of a complete range of Emmedue panels, starting from the production of polystyrene to the construction of the sandwich panel, with a highly sophisticated production process.

Polystyrene Pre-expansion Sintering (molding) Cutting
and shaping Wire unwinding
and straightening Mesh welding
and cutting Panel stitching

Polystyrene

EPS - sintered expanded polystyrene - is a material that is made from styrene.
Polystyrene is obtained through the polymerization of styrene. This, before being expanded, comes in the form of granules of glassy appearance (beads), of various granulometry, from 0.3mm to 2.8mm.

Pre-expansion

Pre-expansion is the process that leads to the formation of polystyrene "beads" through the feeding of energy to polystyrene.

The beads are then placed in contact with water vapor at a temperature above 90°C, in this way the pentane contained in them expands and within them a closed-cell structure is formed which holds the air inside and gives the product its excellent thermal insulation properties.

Sintering (molding)

Sintering is the process of compaction of the polystyrene beads: the expanded and dried beads are injected into the block and subjected again to the action of the steam which causes a further swelling that eliminates the gaps; the beads, welded together, create a homogeneous foam block.

After cooling, these blocks are left to mature and then subjected to cutting into slabs.

Cutting and shaping

The blocks are cut and shaped by a numerical control pantograph with hot wires. The operator according to the design requirements programs the high precision cutter.

Unrolling and straightening of the metal wire

The Emmedue automatic welding system feeds the longitudinal wires through an automatic towing system, which picks them directly from the 20 loading wires and ensures their straightening.

Welding and cutting mesh

The Emmedue automatic welding plant produces flat-galvanized steel meshes consisting of 20 longitudinal wires and transversal wires with variable pitch.

Made to measure, the meshes are stacked on a steel workbench for easy transport near the paneling machine.

Panel stitching

The panel assembly and welding plant is the core of the entire production line: in this phase, the "sandwich" is made of two or four electro-welded meshes and one or two EPS panels, according to the type of panel to be produced.