It can be hard to tell the differences between Styrofoam and Thermocol at just a single glance, but there are key differences between both of them that are crucial to their application in the real world. These differences have led Styrofoam and Thermocol to be one of the largest and most common forms of plastic in the world. So to understand this better,
Let’s start with the most basic questions which are.
Is Styrofoam the same as Thermocol?
No, they are not. Styrofoam is made up of Extruded Polystyrene (XPS) and Thermocol is made up of Expanded Polystyrene (EPS). Both these plastics are derived from the same compound Polystyrene. We create Polystyrene through the polymerization of a petroleum product called styrene, which is just a process of chaining up small molecules(monomers) to create a large number of molecules chemically.
While we are at it, let’s also remove some other basic confusion in naming these similar white foam boards
What is the difference between Thermocol and Thermopor sheets?
Both sheets are made from Expanded Polystyrene(EPS) and are structurally the exact same. The only difference is in the brand names. The former is a brand name from IE while the latter was coined by a German company called BASF.
What is a Thermopore Sheet?
A Thermopor sheet is a foam board also made up of Expanded Polystyrene (EPS). The Polystyrene is expanded into a desired shape and cut into foam boards to make the desired Sheets. These sheets are also known as EPS sheets. The difference between Styrofoam and Thermopor is the same as the difference between Styrofoam and Thermocol. Both are manufactured through two different processes leading to two different products.
Some important information about Polystyrene is that it is the fourth largest number of plastics produced in the world and can be both solid and foamed. You can identify it by its resin identification code or numerical code 6 which is stamped on most Polystyrene products.
But if both Styrofoam and Thermocol are made from Polystyrene, then what’s the difference? The difference is in the manufacturing, the final physical product, and their application.
Image Source: differencebetween.com
Let’s start with the application
Which is better: Styrofoam or Thermocol?
That depends entirely on the application you are going to use them for. Following are the most popular applications of the two foam boards to help you decide
● Styrofoam is a better insulator than Thermocol
Styrofoam having gone through an extrusion process has much less space in its structure than Thermocol. This tight structure means a lower level of space for air pockets and water. While Thermocol being expanded and fused has more air pockets inside it. And since heat is transferred more easily when the medium to travel is air or water, Styrofoam performs better and ensures more insulation from temperature fluctuations
● Styrofoam absorbs less water than Thermocol
Although both plastics are known to absorb water, Thermocol absorbs more water than Styrofoam in general. On average Thermocol absorbs 2-4% of its volume while Styrofoam absorbs only 0.5% of its volume. This is because during the expansion process of the Polystyrene resin, the beads are expanded and joined together but a few air pockets always remain. These pockets are later filled up with water rather than Styrofoam which has fewer air pockets due to the benefit of going through extrusion.
● Styrofoam is dense than Thermocol
This physical attribute can again be explained by Styrofoam having fewer air pockets due to extrusion while Thermocol has more due to the different manufacturing processes. Though having more density does make styrofoam more firm, it does not mean that one is better than the other, because it is easily possible to control and customize the densities of both. If your goal is the transportation of goods, choose the material with more density.
Manufacturing differences between Styrofoam and Thermocol
Two different treating processes of the same compound (Polystyrene) result in two different compounds, each suited to its requirements. The whole process starts with Styrene which first undergoes suspension polymerization, which converts the monomer(styrene) into uniform small beads under high heat which are then washed out, cooled, and dried. These beads are called Polystyrene resin which is the starting ingredient for both Styrofoam and Thermocol
● Manufacturing Thermocol or Expanded Polystyrene (EPS)
Thermocol is acquired by expanding Polystyrene resin(beads) into the desired shape. To do this and achieve the ideal low-density Thermocol, the resin undergoes a process called pre-expansion. This involves heating the resin with steam to achieve proper density before expanding. During this process, it is carefully monitored that the beads do not fuse, and this is made sure of by submerging them in an agitator. This process significantly reduces the density of the resin to 3% of the original volume.
The pre-expanded beads are then left to cool down for 24 hours in a process called aging. After aging, the beads are now ready to be molded into the desired shape. Molding is achieved by subjecting the beads to low-pressure steam, which expands them again and fuses them in a particular shape. After cooling them again, the molded closed-cell EPS foam is cut into the desired shape and coated with a protective epoxy
● Manufacturing Styrofoam Sheets or Extruded Polystyrene (XPS)
Styrofoam sheets are created from the same Polystyrene resin(beads) as Thermocol but with a small change. After the polymerization and refinement of styrene, Polystyrene is acquired in molten form. This molten fluid if left to cool becomes hard plastic that is used for small basic utensils. To get soft foam sheets, an HCFC(Hydrochlorofluorocarbon)142b is dissolved into the molten mixture at a significantly high pressure to make it expand.
The molten resin is then extruded into a narrow slot and then allowed to expand under low pressure. The result is an Extruded Polystyrene(XPS) or Styrofoam sheet which is then cut into the required shapes and sizes.
Different Uses of Styrofoam and Thermocol
It might read like that Thermocol is the lesser of the two plastics but that is not the case. Each Polystyrene plastic is created differently because they are the best at their work. Let’s see how both these plastics help us in our daily life
● What are Styrofoam sheets used for daily?
Styrofoam is used in smaller areas such as basic model-making, and architectural design models, to large-scale installations for building Insulation sheathing, pipe insulation, and highway insulation just to name a few. Styrofoam is also frequently utilized in the food business as packaging or for disposable products such as cups, plates, utensils, and so on. Due to most of the Styrofoam being air, it also does not sink and is also used in life jackets, buoys, or inflatable life rafts.
What size are Styrofoam sheets?
Due to its customizable nature, Styrofoam sheets are available in almost all sizes. The most notable and common sizes for styrofoam sheets are 8’’ x 4’’, 60″ x 40″, 48″ x 36″, and 40″x 32″.
These same measurements in metric equivalents are 2440 x 1220mm, 1524 x 1015mm, 1220 x 915mm, and 1015 x 813mm. Any other non-standard sizes are also available on the market
● What are Thermocol sheets used for?
For a variety of different purposes such as
- In the building industry, EPS or Thermocol is made into large panels known as bead boards that are used to insulate walls.
- For sheathing in air conditioning systems to insulate pipelines and prevent heat loss or heat gain. The sheathing is also done to prevent water condensation on the pipes themselves and prevent water vapors to form icicles
- For severely reducing heat transfer in homes to keep them relatively cool.
- Thermocol products such as packing peanuts are also utilized in packaging materials to avoid damage to appliances such as TVs, refrigerators, fragile cargo, etc.
- Thermocol boxes are also used in packaging fruits, vegetables, meat, and more
What size are Thermocol Sheets?
The most commonly available sizes of Thermocol sheets in Pakistan are 24’’ x 18’’, 18’’ x 18’’, 6’’ x 3’’ and more custom sizes are also available
While both Styrofoam and Thermocol appear from the same plastic. They have different physical properties and manufacturing processes which set them apart. Styrofoam is mostly used for insulation sheathing while Thermocol is used mostly in the food industry for disposables. Learning about the correct usage of both these plastics is also important for their correct use and disposal. If you are searching for premium Styrofoam or Thermocol/Thermopor foam boards at a reasonable price, you can’t go wrong with Style Thermo Insultaions. They are currently the leading manufacturers in Pakistan and are offering the best foam boards in the market which they customize to meet their customer’s specific needs.
