The chemical process of ′suspension polymerisation′ starts when the liquid precursor styrene is mixed with water and stirred. Droplets and, ultimately, compact granules are formed: plastic beads with a size of between 0.3 and 2.5 millimetres. Pentane that has been mixed in as a blowing agent makes the resulting polystyrene granules expandable into a foam. When exposed to pure steam, they expand up to 50 times their volume and form a highly efficient foam granulate material, complete with innumerable little pockets of air. Alternatively, used EPS can be recycled back into virgin granules by means of extrusion (melting).
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