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Kornylak Corporation
400 Heaton St.
Hamilton, OH 45011


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Block Mold: Executive Product Summary

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Executive Product Summary on Block Mold Expanded Polystyrene Machines

Understanding Expanded Polystyrene (EPS) Block Manufacturing Using the Block Mold Line
  • Kornylak Corporation manufactures two types of EPS molding machines: Block Mold and Panel Mold
  • The Block Mold produces solid polystyrene blocks weighing 200 pounds or more with lengths in excess of 16 feet
  • The Panel Mold forms the EPS around a structural element to form a fully insulated building panel
  • The Block Mold uses an ejector to push the finished block out an opposing door
  • The full length lid on the Panel Mold raises while the bottom screen lifts the finished panel for easy removal
  • Both molds utilize tight seals around the various opening to eliminate steam and vacuum losses
  • Either mold can be run automatically or manually
  • Both molds fill with the pre-expanded polystyrene in less than 60 seconds
  • Special stainless steel slotted screens allow steam to be delivered rapidly and uniformly
  • This results in an extremely quick expansion and fusing of the beads creating a superior product
  • Kornylak provides both molds with a master control console
  • Both molds require a vacuum system and special surge tank that can be furnished by Kornylak
  • Both molds require a large quantity of pre-expanded polystyrene beads
  • Kornylak Corporation can provide the pre-expander units and dryer beds
  • Other accessories are available from Kornylak including conveyors, scales, hot-wire cutters, etc.
Block Mold Cycle
  • Pre-expanded styrene is blown into the mold
  • A quick vacuum is pulled removing most of the air
  • Steam is blown in to expand and fuse the polystyrene beads
  • A vacuum is applied to cool and dry the block
  • The block is finished within 6 minutes
  • The door open and the solid styrene block is automatically pushed out
Panel Mold Cycle
  • Structural panel and spacer blocks are placed on the bottom screen
  • The bottom screen is lowered placing the panel in center of the cavity as the lid closes
  • Pre-expanded EPS beads fill the mold on both sides of the structural panel
  • A quick vacuum is pulled removing most of the air
  • Steam is blown in to expand and fuse the polystyrene beads
  • A vacuum is applied to cool and dry the structural insulated panel
  • The panel is finished within 6 minutes
  • The lid rises and the bottom screen lifts the finished panel for easy removal
Advantages
  • Perfect interior bonding
  • Good corner and edge bonding
  • Uniform density distribution
  • Low water content
  • Short production cycles
Product Applications
  • Expanded Polystyrene blocks are cut and shaped into a multitude of products
  • Hot wire cutters are used to cut strips for insulation sandwich panels, decorative moldings, signs, figurines, fluted pillars, garage doors, etc.

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