Expanded polystyrene begins as a polystyrene bead or pellet. The pentane-loaded bead is then exposed to pressurized steam that causes the polystyrene to expand and mold into the desired shape and density needed. Manufacturing EPS does not involve the use of ozone depleting CFCs or HCFCs.

EPS possessed the physical and mechanical properties ideal for most insulating needs. EPS is utilized as insulation in walls, roofs and foundation as well as a component in structural insulated panels, concrete forms and exterior. Other growing applications include flotation devices, cold storage insulation.