Introducing a new type of insulation made from corn

EPS foam, also known as foam plastic, is a primary plastic granule that, after being heated and expanded, becomes a compound containing Bentan gas (C5H12).

The composite composition of ESP particles consists of 90-95% Polystyrene and 5-10% gaseous substances such as pentane or carbon dioxide. EPS foam is cheap, lightweight, but non-biodegradable and difficult to recycle. Thus, German scientists have developed a possible alternative - popcorn foam.

Besides seeds, broken cobs can also be used in production.

Professor Alireza Kharazipour of Georg August University first came up with the idea more than 10 years ago, when he bought a bag of popcorn at the cinema. Since then, Professor Kharazipour and colleagues have devised a method to use this material to replace EPS. Popcorn-based materials are cheap, biodegradable and recyclable.

Scientists start the production process by chopping corn kernels. The team then used pressurized steam to expand them. Next, a binding agent derived from plant proteins is mixed with these bloomed seeds. The mixture will be pressed into the mold. Once the binders have solidified, the scientists remove them from the mold and are ready to use.

According to the team, the material made from corn is better at absorbing heat than EPS, which is not flammable. At the same time, the material can be composted, or chopped for reuse. They are also used to produce biogas or even as animal feed. Besides corn kernels, broken cobs can also be used in production.

This technology was recently licensed to the Bachl Group of Germany. The group will commercialize and use the material in building insulation. Other uses of this material include: Fabrication of protective/insulating packaging, sports equipment parts and automotive parts.

'This is my contribution as a scientist for a clean environment, free of plastic products. This new process, based on the plastic industry process, enables cost-effective industrial scale production of insulation panels.

Especially in the field of construction insulation, this material ensures natural insulation. In addition, these products have water-repellent properties, opening up many practical application opportunities and prolonging their use time," said Professor Kharazipour.