Frequently Asked Questions

Many types of rigid and soft foams can be cut with our hot wire cutters, however due to the chemicals in many of these foams that off-gas when cutting, we only recommend cutting the following types of foams:

  • Expanded Polystyrene (EPS)
  • Expanded Polystyrene Foam
  • Extruded Polystyrene (XPS) also know as “blue” and “pink” board.
  • Extruded Polystyrene Foam

Most areas of the world use polystyrene for food service products, packaging, construction and marine uses. This means a foam block molder is usually not far from your location no matter where in the world you are located. In an effort to keep this list current please contact us if you know of any bad links posted here, or if there is a company that should be on this list.

AUSTRALIA

Andpak
Austral
ECO ICF Builders and Supplies Pty Ltd
FOAMEX
Hi-Tek Foamworks
National Polystyrene Systems
Polyfoam
RMAX 

BELGIUM

Isodec
Isomo

CANADA

AR EPS Foam
Eco-Block
Beaver Plastics
Isolofoam
Mansonville Plastics
Truefoam
Newfoundland Styro 
Plasti-Fab Ltd.

CAYMAN ISLANDS

Flowers Foam

COLOMBIA

Industria de Poliestireno Expandible de Colombia

CZECH REPUBLIC

Jackon 
StyroChem

DENMARK

StyroChem

DOMINICAN REPUBLIC

POLYCONSTRUCCIONES: 809.696.9317; SANTIAGO

ECUADOR

Aislapol: 593.9.469.3253
Plastex: 593.2.267.7019, Catarama Y Maldonado; 593.2.267.4997, Quito Pichincha
Poliexpandidos Cia LTDA

FINLAND

StyroChem

GERMANY

StyroChem 

INDIA

RHYNO

IRELAND

Airpacks 

JAMAICA

Free Form Factory 

MEXICO

ACH Foam
Createc Corporation 
Fanosa
Frigolit
QualyPanel

NEW ZEALAND

Barnes Plastics
Bondor

POLAND

StyroChem
Arbet 

PUERTO RICO

Flexible Packaging Group 
Foam Pack, Inc. 

RUSSIA

StyroChem 

SAUDI ARABIA

IBSF 
Sabic 

SLOVAKIA

Polyform

SOUTH AFRICA

Automa Multistyrene 
Cumulus Insulation
Isolite 
Isowall 
Hebcooler 
Polystyrene Center CC 
Sagex
Technopol (SA)
Twokay Trading

SPAIN

StyroChem 

SWAZILAND

Isolite 

UNITED KINGDOM

StyroChem 
Styro-tech 
Custom Pac 
Chaseway Packaging 
Molygran and Co. 

European Manufacturers of EPS

Head Office 

AUSTRIA

Guteschutzgemeinschaft Polystyrol-Hartschan G.P.H 

BELGIUM

Styfabel 

CZECH REPUBLIC

Czech EPS Association 

DENMARK

Plastindustrien i Danmark

FINLAND

FIPIF Finnish Plastic Industries Federation 

FRANCE

Syndicat National des Plastiques Alveolaires: 33.0.145.20.4268 15

GERMANY

Industrieverband Hartschaum e.V 

GREECE

Hellenic Association

ITALY

AIPE Associazione Italiana Polistirolo Espans

LITHUANIA

Lithuanian EPS Association

NETHERLANDS

Stybenex

NORWAY

Ms. Anne Kjerstin Frydendal Plastindustriforbundet: 47.23.08.7800

POLAND

Stowarzyszenie Producentow Styropianu 

PORTUGAL

ACEPE Associacao Industrial do Poliestireno Expandido

SLOVAKIA

Zdruzenie EPS.SR Novozamocka: 179 94901

SPAIN

ANAPE Associacion Nacional de Poliestireno Expandido 

SWEDEN

Plast och Kemibranschema Byggplastavdelningen

SWITZERLAND

EPS Verbank Schweiz Bahnhofstrabelel: 41.0.41.850.1591

TURKEY

Polistiren Üreticileri Dernegi (PÜD)

UNITED KINGDOM

The British Plastics Federation 

International EPS Organizations

EPS Association of South Africa

Most areas of the world use polystyrene for food service products, packaging, construction and marine uses. This means a foam block molder is usually not far from your location no matter where in the world you are located. Here is a comprehensive list of expanded polystyrene (EPS) foam block molders throughout the United States. Most likely you will find several block molders serving your area to choose from. We usually recommend purchasing dry “virgin” foam in smaller size beads (A,B,C A is largest – C smallest) weighing between 1 and 2 lbs./cubic foot nominal, .9-1.8lbs. actual. This list of expanded polystyrene (EPS) foam block molders / manufacturers is for reference only, and to the best of our knowledge is accurate and up to date.

ALABAMA

EFP

ALASKA

Insulfoam

ARIZONA

Insulfoam
Prowall
StarRfoam

ARKANSAS

Drew Foam
Noark Foam

CALIFORNIA

Astrofoam Molding
Atlas EPS
Insulfoam

COLORADO

ACH Corporate
Insulfoam

CONNECTICUT

Polar Industries

FLORIDA

Carpenter Foam
Cellofoam
Imperial Foam
Insulfoam
Royal Foam

GEORGIA

Cellofoam
PermaTherm
Georgia Foam
ACH

IDAHO

Foam Molders Inc.
Northwest Foam
Foam Molders Inc.

ILLINOIS

DiversiFoam
ACH

INDIANA

Cellofoam
EFP

IOWA

ACH
Iowa EPS

KANSAS

ACH

KENTUCKY

Creative Packaging

MASSACHUSETTS

Insulation Technology

MICHIGAN

Arvron
Atlas EPS
Harbor Foam
Michigan Foam Products

MINNESOTA

DiversiFoam
Plymouth Foam
Poly-Foam
Styrotech

MISSISSIPPI

Perma R Products

MISSOURI

Atlas EPS
Versa Tech

MONTANA

Big Sky Insulations

NEBRASKA

Insulfoam

NEVADA

ACH

NEW MEXICO

American Polysteel

NEW YORK

Shelter Enterprises
Thermal Foams
Cellofoam

NORTH CAROLINA

Carpenter Company

OHIO

Plymouth Foam

OKLAHOMA

Cellofoam

OREGON

Northwest Foam

PENNSYLVANIA

Carpenter Company
Insulation Corp of America
Insulfoam
OPCO
Thermal Foams

PUERTO RICO

Flexible Packaging Group
Foam Pack

RHODE ISLAND

Branch River Foam

SOUTH DAKOTA

Benchmark Foam
North Central Foam

TENNESSEE

Drew Foam
EFP

TEXAS

Alamo Foam
Eco-Block
Houston Foam
Power Foam
StarRfoam
Therma Foam

UTAH

ACH
Isulfoam

VIRGINIA

Cellofoam
Atlas EPS
Mid-Atlantic Foam
Tri-State Foam

WASHINGTON

Isulfoam

WISCONSIN

ACH
Plymouth Foam

Expanded polystyrene (EPS) foam is the most common foam cut for architectural shapes, structural insulated panel systems (SIPS), insulated concrete forms (ICF), precast concrete molds and models, theming, and sign making. EPS is technically a plastic. The word ‘plastic’ comes from Greek plastikos, which means capable of being molded. The freedom to be creative with custom designs is a major reason why we find EPS so valuable today. It is also interesting to know that EPS foam is the same material (polystyrene) used to make hard shell CD cases and other household products. To find polystyrene in everyday products, look for recycling number ‘6’.

EPS Characteristics
  • Light Weight: Typically 1 lb. – 2 lbs. / cubic foot
  • Highly Insulative: Because there is no thermal drift, 1 inch provides lifetime R-3.6 to R-4.2 values (depending on density)
  • Environmentally Friendly: EPS has always been CFC- and HCFC-Free
  • Manufactured Locally: Hundreds of plants throughout the world

Chemical Properties

Expanded polystyrene is resistant to water and all aqueous solutions of salts, alkalis, and acids. Essential oils such as those present in both the peel of citrus fruits and whole-fruit drinks attack expanded polystyrene, but it is resistant to both vegetable and animal fats. It is also resistant to mineral waxes of the kind used to guard against corrosion, provided they contain no solvent.

Since most organic solvents attack expanded polystyrene, particular care must be taken in the choice of adhesives, paints, coatings, and mold release agents. Plastics containing plasticizers (e. g. flexible PVC) should not be kept in contact with expanded polystyrene because of the risk of plasticizer migration.

Biological Effects

Small amounts of pentane vapors escape from polystyrene while it is stored and being processed. Ventilation should be provided, particularly when expanded polystyrene is cut with hot wires, since pentane and small amounts of styrene can be released. The threshold values, workplace limits, etc. for both pentane and styrene must be observed.

The National Institute for Occupational Safety and Health (NIOSH) has established Recommended Exposure Limits (REL’s) for average airborne concentration of pentane at 120 ppm, with a ceiling limit of 610 ppm (15 minute). Typically EPS forming and cutting facilities operate at levels well under these limits. (PDF document with findings from a NIOSH inspection of a foam expanding and cutting facility.)

Expanded polystyrene has no nutritive value for animals. It does not rot, is not soluble in water, and it does not give off water-soluble substances which could lead to groundwater contamination. If local regulations allow, waste expanded polystyrene can be safely disposed of with household garbage by landfill. Expanded polystyrene has been manufactured and processed for over fifty years and during that time no harmful effects on health have been recorded

Fire Characteristics

Like all organic materials, expanded polystyrene is combustible, and like most packaging materials it is also flammable. Its burning behavior depends largely on the polystyrene grade in question. A distinction has to be made between products without fireproofing additives and products containing additives. Expanded polystyrene that contains flame retardant makes it more difficult to ignite and slows the spread of flame noticeably.

Sources: EPS Recycling International http://www.epsrecycling.org,
Chemical, Biological and Fire Data Courtesy of BASF Corporation, and
Centers for Disease Control and Prevention http://www.cdc.gov/niosh/homepage.html

Styrene is composed of Benzene (liquid) and Ethylene (gas), both of which are petroleum products. EPS begins as a styrene monomer which goes through a process where the styrene monomers link into larger molecules called polystyrene.

Expanded polystyrene or EPS foam is made from polystyrene pellets or beads that are puffed up with steam. The process is similar to cooking rice with steam. Usually a small amount (approx 4%-6%) pentane or another “blowing agent” is added to the hard polystyrene pellets to enable the expansion process. When these independent foam beads are in a mold they take the shape of the mold and hold that shape when they dry and cool down.

The polystyrene beads grow to more than 40 times their original size and when the process is complete the usable EPS is about 98% air* which gives it features that are desired. Expanded polystyrene is a rigid, insulating, light weight, and biologically friendly foam.

Source:  European Manufacturers of Expanded Polystyrene: www.eumeps.construction

Coating foam can be done with a variety of coating products depending on your application.

Typically foam architectural elements are coated with an exterior insulation and finish system (E.I.F.S.) synthetic stucco coating. These coatings consist of a base coat adhesive which includes embedded mesh. The base coat and mesh give the foam structural integrity, on which a colored, textured finish coat is applied.

Foam is also coated with epoxy, polyurea, or polyurethane coatings for a smooth hard plastic finish. These coatings also give the foam structural integrity and upon which paint or other finish is applied for theming, sign making, and architectural elements. Epoxy, polyurea, and polyurethane finishes are also used for precast concrete applications to make a smoother and longer-lasting surface for casting concrete and glass fiber reinforced concrete (GFRC).

For most applications the foam cut on your Hotwire Direct machines will need to be coated in some manner. There are many expanded polystyrene EPS foam coatings available, each with it’s own advantages. Coatings can add structural strength, a solid look and feel to the foam and ultimately beautify the product.

This is a courtesy list of coating suppliers many of our customers use, and is meant to be informative only and in no way implies endorsement by Hotwire Direct. Please contact these companies with your questions to find the best coating solution for your particular application.

Epoxy Coatings

Fister
Product: Armorgard™
www.fisterinc.com

Polyurea, Polyurethane

Futura Coatings
Product: Styrothane
www.futuracoatings.com

Industrial Polymers
Product: Polyurethane (Styrospray 1000)
www.industrialpolymers.com
Phone: 800.766.3832

Finishes and Paints

LuminOre
Product: Metal Spray Applied Finishes
www.luminore.com
Phone: 760.431.7705

Modern Masters
Product: Array of Metallic and other Theming Paints
www.modernmastersinc.com
Phone: 800.942.3166

Stone and Cementitious Coatings

ArcusStone
Product: ArcusStone
www.arcusstone.com
Phone: 415.339.4060

Marbelite
Product: Styrocrete
www.marbelite.com
Phone: 800.348.3993

Tuscan Stoneworx
Product: Various
www.tuscanstoneworx.com/
Phone: 888.368.9494

Release Agents (for precast concrete applications)

Cresset
Product: Crete-Lease
www.cresset.com

Synthetic Stucco

ADEX
Product: Various
www.adex.com
Phone: 866.900.2339

Dryvit
Product: Various
www.dryvit.com
Phone: 800.556.7752

Master Wall
Product: Various
www.masterwall.com
Phone: 800.755.0825

Omega Products
Product: Various
www.omega-products.com
Phone: 800.600.6634

Parex
Product: Various
www.parex.com
Phone: 800.537.2739

Senergy
Product: Various
www.senergy.master-builders-solutions.com/en
Phone: 800.221.9255

Sto
Product: Various
www.stocorp.com
Phone: 800.221.2397

Because EPS foam is expanded, it consists of about 90% air. This is beneficial for most purposes that it is used for, however, this also means it will use high volume for shipping. You can use a foam compactor for compressing the air out of the waste which helps with transportation issues.

Keeping EPS foam out of the landfills is a primary objective of the EPS Molders Association, of which Hotwire Direct is a member. For recycling, many creative options exist.

Because EPS can be recycled, and by conserving and re-using resources we are doing our part to ensure a brighter future for our children. When using EPS it is important to consider the life cycle possibilities of the material itself. The end of (or waste from) an EPS product in one form can become a new product in another form. By actively recycling EPS we can create a good name for the industry, as well as promote creative problem solving, economic activity, and more.

How To Recycle

Return to Block Molder
Many of our customers keep their waste EPS foam out of the landfill by returning it to their foam block supplier when taking delivery of new blocks in a swap. Some EPS foam block molders use the clean waste scrap for making a regrind foam product.

EPS Packaging Association
This organization is dedicated to promoting the use of EPS including recycling and will help you to find recyclers in your area.
http://www.epspackaging.org/

Yes, most products that we ship via FedEx can be purchased directly online with a credit card. Please contact us if you have any questions on products before purchasing.

Yes financing is available in the USA. We have partnered with outside companies who specialize in equipment financing. Get into brand new equipment on a budget. Hotwire Direct works with Suncoast Equipment Finance (USA only).

Suncoast Equipment
Existing Businesses:

$25K – $250K
1 page application
Terms – out to 84 months
Approvals in 1-3 hours
Progress payment terms to Hotwire Direct OK
“0” down and deferred payments OK
Capital Lease structure ($1.00 buyout), Operating lease structure (FMV)
Typically they look for 3 years “time in business”, clean D&B with good paydex, comparable business debt with favorable pay history. Clean personal credit where applicable.

New Businesses:

Other financing for “New Business” and “lesser credits” available at different pricing, please call for a quote.


For more information please contact Suncoast Equipment Finance contact Gearry Russell:

(877) 724-5949
Fax 813-443-8259
[email protected]