XPS Foam Board Production Line
Tandem extrusion lines for XPS insulation boards — CO₂-based foaming, flat-die forming, cutting, edge profiling and in-line recycling of trim waste.
XPS Foam Board Production Lines We Supply
XPS Foam Board Production Process
Raw material dosing → first-stage extruder (melting and mixing) → blowing agent injection → second-stage extruder (cooling and pressure build-up) → flat die → calibrating and forming → cooling and haul-off → cutting to width and length → edge profiling and surface finishing → stacking and packing. Trim and off-cut waste is crushed and fed back into the line.
Tandem Extrusion: Twin-Screw or Single-Screw First Stage
XPS is made on two extruders in series. The first stage melts the polystyrene and mixes in the additives and blowing agent; the second stage cools the melt and builds the pressure needed for even foaming at the die.
- Twin-screw first stage + single-screw second stage — the standard for high-output lines: better mixing, more stable cell structure and a wider choice of formulations.
- Single-screw + single-screw — an economical configuration with a lower investment, suited to smaller outputs.
Blowing Agent: CO₂ Foaming
Most new lines use CO₂-based foaming, with alcohol as a co-blowing agent. It is environmentally preferred and lowers the cost of the blowing agent compared with HFC-based foaming. Some older and low-cost lines still use HFCs or butane, and many lines are built to switch between CO₂ and HFC. Rules on blowing agents differ by country — tell us your market and we configure the injection system to match.
XPS Board Range and Standards
- Thickness: usually 20–60 mm; up to 30–120 mm with an HFC-assisted foaming process where regulations allow
- Width: 600–1200 mm
- Density: 30–45 kg/m³
- Edges: straight, shiplap or tongue-and-groove; smooth-skin or grooved surface
- ASTM C578 (US) covers rigid cellular polystyrene thermal insulation — moulded (EPS) or extruded (XPS) boards — for use from about −54 to +74 °C.
- EN 13164 (Europe) is the specification for factory-made extruded polystyrene foam (XPS) thermal insulation products for buildings.
Tell us the standard and the blowing-agent rules in your market: they decide the formulation, the density range and the injection system.
Capacity, Site and Project Timeline
- Output: 500–2,000 kg/h
- Delivery: about 4–6 months — extrusion lines take longer to build
- Installation and commissioning: usually 2–3 engineers on site for 2–3 months
- Site: 3,000–5,000 m² of buildings, about 0.7–1.3 ha (10–20 mu) including storage
These are typical figures; your output, products and site decide the final configuration and schedule.
Every line is configured to your board range, target output and the raw materials and blowing agents available in your market. Send us your requirements and we will propose a configuration. For other plants, see our building material production lines.
What to Send for a Quotation
- Board thickness, width and density range, edge profiles and surface finish
- Target output (kg/h or m³ a year)
- The product standard and blowing-agent rules in your market
- Raw materials: virgin polystyrene and any recycled material you plan to use
- Power supply and site dimensions
- Destination country and target timeline
With your output target, destination country and timeline we can start, and you receive a written sourcing report within 48 hours of a complete requirement brief.
Building a complete insulated wall system? See our EPS sandwich cement wall panel production line, the MgO board production line for fire-resistant facing boards, and all our building materials production lines.
Planning a new plant? Read our XPS board plant setup guide — blowing agent rules, extruder choice, site and timeline.
One Partner from Requirement to Running Line
- Requirement review — capacity targets, site conditions and budget
- Equipment selection and supplier matching — vetted Chinese manufacturers
- Plant layout planning — civil works drawings issued early
- Quality inspection and factory acceptance testing before shipment
- Export documentation and freight coordination
- Installation, commissioning and operator training
Frequently Asked Questions
Twin-screw or single-screw first stage — which do I need?
For high output and stable quality across a range of formulations, a twin-screw first stage. For a smaller first plant, a single-screw tandem line keeps the investment down. We recommend one after reviewing your target output and products.
Can the line run on CO₂?
Yes. CO₂-based foaming with alcohol as a co-blowing agent is the standard on new lines. Lines can also be built to switch between CO₂ and HFC where your market allows.
What thickness and density can we produce?
Usually 20–60 mm thick, up to 30–120 mm with an HFC-assisted process, 600–1200 mm wide, at 30–45 kg/m³.
Can we use recycled polystyrene?
Edge trim, off-cuts and start-up scrap from the line are crushed and fed back in. Outside recycled material can be blended in at a set ratio once we have assessed its moisture and cleanliness — moisture and contamination are what damage the cell structure.
What output can a line reach?
Our lines are commonly built for 500–2,000 kg/h.
How long does a project take, and who do you send?
Plan on about 4–6 months for delivery — extrusion lines take longer to build. We usually send 2–3 engineers for 2–3 months of installation and commissioning.
What do you need to prepare a quotation?
Your board thickness and width range, target output, blowing agent rules in your market, project location and planned timeline.
Request an XPS Board Line Proposal
Tell us your board range, target output and market. We respond within one business day.
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