Plant Overview

PM2 Manufacturing Plant

Our plant is currently equipped with a single product line to produce panels for our projects in Malaysia.

As the production process is semi-automated, thus, it requires minimal workers to operate. Our plant can produce up to 1,600 square meter of panels per-day on a normal 8 hour shift.

Production Process

EPS (Sintered Expanded Polystyrene) is a material produced from styrene, a monomer derived from petroleum, but also found in foods such as wheat, strawberries, meat and coffee. Polystyrene is obtained through the polymerization of styrene. Before being expanded the polystyrene is in glassy granule form (beads), with size ranging from 0.3 to 2.8 mm.

At this stage, all the raw material will be screen through to ensure that the polystyrene are not contaminated and in its purest form.

Pre-expansion, the physical-chemical process that leads to the formation of the polystyrene beads, takes place by heating the polystyrene – the raw material – without using CFCs. The beads thus obtained are then treated with water vapour at temperatures above 90°C to allow the pentane they contain to expand causing an increase in their initial volume by up to 20-25 times, forming an internal closed cell structure that holds air and gives the product its excellent thermal insulation properties.

After pre-expansion the beads are subjected to a period of ageing and then are conveyed to silos to be air dried, here excess moisture is removed. This provides the stability required for the next stage of the process.

During the “sintering” (moulding) process, the expanded polystyrene beads are welded and compressed. The expanded and dried beads are injected into a mould and again, subject to vapour that causes a further swelling. This process will completely close the interstices between the beads that, after welded together, create a homogeneous block of foam. After cooling, these blocks are left to cure before final cutting into slabs.

The blocks are then cut and shaped by a CNC hot-wire, high-precision cutter which is programmed by the operator according to specific job requirements.

The automatic welding plant is equipped with a wire feeding mechanism which pulls the longitudinal wires directly from 20 loading coils and straighten them.

The automatic welding plant produces galvanized flat steel meshes, made up of 20 longitudinal wires and cross wires at variable pitch.

The meshes are automatically produced to size, then lifted by an automatic device and stacked on a steel pallet ready for transfer to a panel machine.

Our automatic assembly and welding plant for spatial panels with double connectors lies at the centre of our entire production line because this machine produces the sandwich panels made up of two or four welded wire meshes and one or two sheets of polystyrene depending on the type of panel to be produced.

Emmedue® Technology

Through our partnership with M2 Emmedue S.p.A Italy, we have entered into a technology transfer agreement with them inclusive of the purchase of EMMEDUE®’s production line.

EMMEDUE®’s solution has been used in more than 40 countries worldwide at their respective plant.

EMMEDUE® technology is the result of more than 30 years of experience focusing on the study of this unique technology combined with their vast knowledge and understanding in the construction industry gathered from their business partners around the world. Through this wealth of knowledge, EMMEDUE® was able to provide the best solution in meeting its customers’ specific construction needs.

Emmedue® Technology for PM2 Panels