Expanded Polypropylene (EPP) is expanded PP. So what is polypropylene (PP)? Polypropylene is a kind of hemicrystalline thermoplastic plastics. Most commercial polypropylene is isotactic and has an intermediate level of crystallinity between that of low-density polyethylene and high-density polyethylene. PP is normally tough and flexible. This allows polypropylene to be used as an engineering plastic, competing with materials such as EPPABS. It is reasonably economical, and can be made translucent when uncolored but is not as readily made transparent as polystyrene, acrylic, or certain other plastics. It is often opaque or colored using pigments. And it has good resistance to fatigue. Due to its impact resistance, engineering properties and corrosion resistance, it’s widely applied in industrial circles.

By combining polypropylene resin with magic dust, and applying heat, pressure and CO₂ in an autoclave, the material is formed into small plastic beads. These small, closed-cell foam beads are injected into a steam chest to create parts custom moulded into complex shapes using steam heat and pressure.

Expanded Polypropylene shares many of the same properties as EPS. EPP Recycling It is closed cell foam, which is flexible and lightweight.  An environmentally-friendly product, it can be recycled easily, and is 100% non-toxic. Expanded Polypropylene provides outstanding energy absorption characteristics, weight to strength ratio, high thermal resistance, and are resistant to water, oils and most chemicals and are available in a variety of densities. EPP has very good impact characteristics due to its low stiffness; this allows EPP to resume its shape after impacts. EPP is extensively used in model aircraft and other radio controlled vehicles by hobbyists.

EPP was first developed in the 1970's by JSP, as a result of research into new forms of polypropylene. The material's first applications were for automotive products in Japan in 1982. Demand for EPP has since increased dramatically in all regions of the world based partly on the need of auto makers to improve energy management functions whilst reducing weight and improving environmental benefits. The first automotive application for EPP was for an energy absorbing component in a bumper system. EPP is now widely utilized for numerous other automotive parts and systems, including seating and other interior components. The global expanded polypropylene foam market was valued at US$1,186.6 million in 2022 and is expected to reach US$2,581.9 million by 2032.

The GREENMAX Zeus foam recycling machine breaks the waste EPP into pieces, which are then compressed into EPP ingots by the machine and extruded by the screw. After processes such as granulation, these foam ingots will become EPP particles, which can be used to make other recycled products.