Expanded Polypropylene (EPP) is a highly versatile, lightweight, and durable foam material known for its excellent impact resistance, thermal insulation, and energy absorption properties.
It is widely used in industries such as automotive, packaging, consumer goods, and construction due to its recyclability and sustainability benefits.
As demand for EPP grows in 2025, manufacturers are innovating with advanced production techniques, eco-friendly formulations, and customized solutions.
What is Expanded Polypropylene？
Expanded Polypropylene (EPP) is a lightweight, durable, and resilient foam plastic made from polypropylene.
It is known for its excellent impact resistance, energy absorption, thermal insulation, and buoyancy properties.
Key Characteristics of EPP:
- Lightweight – Low density but strong, making it ideal for weight-sensitive applications.
- Impact Resistance – Absorbs shocks effectively, used in automotive bumpers, helmets, and protective packaging.
- Thermal Insulation – Resists temperature changes, useful in food packaging and HVAC systems.
- Chemical & Moisture Resistance – Does not degrade easily when exposed to water, oils, or chemicals.
- Recyclable & Eco-Friendly – Can be reused and recycled, making it more sustainable than EPS (Styrofoam).
- Buoyancy – Used in marine and aquatic safety equipment.
Common Applications:
- Automotive: Bumpers, seat cushions, headrests, and door panels.
- Packaging: Protective cases for electronics, medical devices, and fragile goods.
- Consumer Goods: Bicycle helmets, toys (e.g., LEGO-like blocks), and sports equipment.
- Industrial: Insulation panels, HVAC components, and shipping containers.
Advantages of Expanded Polypropylene (EPP) Foam
EPP foam is a versatile material with unique properties that make it superior to many other foams (like EPS, PU, or PE). Here are its key advantages:
1. Exceptional Impact Resistance & Energy Absorption
- High resilience: Returns to its original shape after compression, unlike EPS (Styrofoam), which crushes.
- Ideal for protective packaging (electronics, medical devices) and automotive safety (bumpers, child seats).
2. Lightweight Yet Durable
- Low density (as light as 20 g/L) but strong, reducing weight in automotive and aerospace applications.
- Better strength-to-weight ratio than EPS or PU foam.
3. Excellent Thermal Insulation
- Maintains performance in -30°C to 130°C (-22°F to 266°F).
- Used in food packaging, HVAC systems, and cold chain logistics.
4. Chemical & Moisture Resistance
- Waterproof & oil-resistant—unlike EPS, which absorbs moisture.
- Resists acids, alkalis, and solvents, making it suitable for marine and industrial uses.
5. Long Lifespan & Reusability
- Does not degrade easily—can be washed, sterilized, and reused (unlike single-use EPS).
- Common in reusable packaging (e.g., logistics containers).
6. Eco-Friendly & Recyclable
- 100% recyclable (unlike cross-linked PE foam).
- Some manufacturers offer bio-based EPP from renewable sources.
- Lower environmental impact than EPS (Styrofoam).
7. Customizable & Easy to Mold
- Can be molded into complex shapes (e.g., car seat cushions, helmet liners).
- Available in multiple colors for branding or functional coding.
8. Buoyancy & Floatation Properties
- Closed-cell structure makes it ideal for life jackets, floating docks, and marine safety gear.
9. Vibration Damping & Noise Reduction
- Used in automotive interiors (dashboards, door panels) and industrial machinery to reduce noise.
Comparison with Other Foams
| Property | EPP | EPS (Styrofoam) | PU Foam | PE Foam |
|---|---|---|---|---|
| Impact Resistance | Excellent | Brittle | Good | Moderate |
| Rebound Ability | High | None | Low | Low |
| Water Resistance | Yes | Absorbs water | Yes | Yes |
| Recyclability | Fully recyclable | Limited | Hard to recycle | Hard to recycle |
| Temperature Range | -30°C to 130°C | -50°C to 70°C | Degrades at high temps | -40°C to 80°C |
| Cost | Mid-high | Low | Mid | Mid-high |
Best Expanded Polypropylene manufacturers 2025
1. JSP Corporation (Japan)
Headquarters: Tokyo, Japan
Founded: 1962
Key Products: ARPRO® EPP, EPP beads, automotive components
JSP’s core technologies revolve around various foam plastics, but its most renowned and influential product is EPP (expanded polypropylene). This material offers excellent properties, including lightweight, high impact resistance, excellent energy absorption, heat resistance, and recyclability.
Its products are widely used in the following areas:
Automotive Industry (one of the largest markets):
Bumper core: Absorbs collision energy, protecting pedestrians and the vehicle structure.
Headrests and seats: Provide lightweight, comfortable support.
Tool boxes and trunk linings: Lightweight, durable, and impact-resistant.
Door panels and interior linings: Provide sound insulation and shock absorption.
With the development of new energy vehicles, lightweighting is particularly important for improving driving range.
Packaging and Logistics:
High-performance cushioning packaging for precision instruments (such as semiconductors), medical devices, and fresh food, providing superior protection.
Reusable logistics boxes and transfer boxes are durable and hygienic.
Building Materials:
Products like ARPRO-LITE, used as infill in concrete slabs, can significantly reduce the overall weight of buildings, save on building materials (such as steel and concrete), and improve sound and thermal insulation.
Consumer Goods and Household Goods:
Toys (such as the famous “crawling mat”), safer child car seats, sports protective equipment (such as helmet liners), furniture, and household items.
Other Industrial Applications:
Incubators, cleaning equipment, and other industrial components requiring lightweight, high-strength, and thermal insulation properties.
2. Epsole (China)
Headquarters: Hangzhou, China
Founded: 2011
Key Products: EPP, EPP beads, Machines
Similar to the global giant JSP, Epsole’s core material is EPP. EPP’s lightweight, high impact resistance, heat resistance, and recyclability make it an ideal material for numerous industries.
Its products are primarily used in the following areas:
Automotive (core market):
The company is a partner of many domestic and international automakers and Tier 1 suppliers.
Products include: automotive bumper cores, impact blocks, headrests, seat frames, side panels, tool boxes, trunk mats, and more.
The key benefits of Epsole lie in its lightweight construction (helping to reduce fuel consumption and improve electric vehicle range), energy absorption (protecting pedestrians and passengers), and sound and heat insulation.
Packaging and Logistics:
High-performance, cushioning, and shock-absorbing packaging for precision instruments, electronic products, medical devices, and cold chain fresh produce.
Reusable, environmentally friendly logistics boxes and turnover boxes are durable and sturdy, significantly reducing packaging costs.
Consumer Products and Others:
Children’s Products: Baby crawling mats, toys, and child safety seat inserts (due to their non-toxicity and impact resistance).
Sporting goods: Helmet linings, protective gear, etc.
Household appliance linings, thermal insulation boxes, etc.
3. Knauf Industries (Germany/France)
Headquarters: Forbach, France
Founded: 1932
Key Products: EPP automotive parts, packaging solutions
Knauf Industries’ core business is utilizing foaming technology to produce lightweight, high-performance plastic solutions. Its product line focuses on two main materials:
Expanded Polystyrene (EPS) – A Traditional Area of Strength
Building Insulation: This is one of Knauf’s largest markets. Knauf produces insulation boards for exterior walls, roofs, and floors, offering excellent thermal insulation.
Packaging: Knauf provides shock-absorbing packaging for electronics, home appliances, food (such as seafood coolers), and pharmaceuticals. The famous “white foam box” is made of EPS.
Geology and Civil Engineering: EPS is used to create lightweight fill materials (EPS blocks) for infrastructure projects like roads, bridges, and stadiums, reducing foundation loads.
Expanded Polypropylene (EPP) – A Core Growth Area
Automotive: This is EPP’s most important application area. Products include:
Bumper Core and Impact Pads: Absorb collision energy.
Headrests and Seat Frames: Lightweight and safety-compliant.
Tool Boxes and Battery Pack Housings: Protective housings for battery packs in new energy vehicles, in particular, are a rapidly growing segment.
Interior Parts: Door panel linings, trunk mats, etc.
Advantages include lightweighting (improving fuel efficiency or electric vehicle range), safety (excellent energy absorption), and sustainability (recyclability).
Packaging & Logistics: High-performance, reusable shipping packaging and turnover boxes for industries such as automotive parts and precision instruments.
Consumer Products: Child safety seats, toys, furniture, etc.
4. Sonoco Products Company (USA)
Headquarters: Hartsville, South Carolina, USA
Founded: 1899
Key Products: Protective EPP packaging, automotive components
Sonoco’s business is extensive and is primarily divided into two divisions: Consumer Packaging and Industrial Packaging.
- Consumer Packaging
We specialize in packaging for end-consumer products such as food, beverages, health supplements, and personal care products.
Paperboard and Composite Cans: This is Sonoco’s traditional strength. We produce composite cans, paper tubes, and containers for packaging foods (such as chips, nuts, and cookies), beverage concentrates, pet food, and milk powder.
Rigid Plastic Containers: We produce a variety of blow-molded and injection-molded plastic cans, bottles, and boxes for food, health supplements, personal care, and cosmetics.
Flexible Packaging: We provide flexible plastic and film packaging for food, pet food, and medical supplies, offering freshness preservation, moisture resistance, and attractive printing.
Recycling and Sustainability Services: We operate recycling facilities and provide collection services for major retailers and consumer product companies.
- Industrial Packaging: We focus on protecting and supporting the needs of industrial products during transportation, storage, and display.
Paper Cores, Tubes, and Sticks: This is Sonoco’s global leadership segment. Our products are used to wrap cores for textiles, films, paper, carpets, tapes, fireworks, and other materials.
Industrial Blow-Molded Plastic Containers: Large plastic drums and containers for chemical, food, and pharmaceutical ingredients.
Protective Packaging: We produce cushioning packaging materials made of foam, paper, and molded fiber to protect electronics, appliances, automotive parts, and other products during transportation.
Display and Retail Services: We design and produce product display racks and shelf-ready packaging for retail stores.
5. Hanwha Corporation (South Korea)
Headquarters: Seoul, South Korea
Founded: 1952
Key Products: EPP for automotive, appliances, and industrial uses
Hanwha‘s foam materials business directly competes with JSP and Knauf Industries, mentioned previously, and its product lines are highly similar:
Expanded Polypropylene (EPP)
Automotive Parts: This is the most important application area. It supplies bumper cores, side impact beams, seat frames, headrests, tool boxes, and other products to automakers such as Hyundai and Kia, providing lightweight and impact-absorbing features.
High-End Packaging: Reusable, cushioning and shock-absorbing packaging for precision instruments, electronics, and medical devices.
Logistics Containers: Strong, lightweight, and durable reusable logistics containers.
Consumer Goods: Child safety seat cores, toys, and furniture accessories.
Expanded Polyethylene (EPE)
Packaging Materials: This common white, soft foam (commonly known as “EPE”) is widely used for protective packaging and filling for furniture, glass, and electronics.
Building Insulation: Used for floor heating insulation pads, etc.
Sporting Goods: Yoga mats, linings for sports protective gear, and more.
6. Furukawa Electric Co., Ltd. (Japan)
Headquarters: Tokyo, Japan
Founded: 1896
Key Products: EPP for electronics, automotive, and industrial uses
Furukawa Electric Co., Ltd.’s core business does not include foamed plastics like JSP or Knauf.
Its primary strengths lie in metal processing (copper, aluminum, and alloys) and fiber optics, not in foaming organic polymer materials.
However, Furukawa Electric has a very important and lucrative business that is literally related to “foam,” but differs significantly in materials and applications:
Furukawa Electric’s “Foam” Business: Metal Foam
Furukawa Electric is a global leader and major producer of aluminum foam technology. This business is typically managed under its Functional Materials Division.
- What is the Product?
Material: Aluminum foam. This is an ultra-light metal material composed of numerous bubbles within an aluminum matrix.
Trade Name: Furukawa Electric’s aluminum foam product brand is typically referred to as “ALPORAS.”
- Key Features and Advantages:
Extremely Lightweight: Its density is only 1/5 to 1/3 that of aluminum, even lighter than water (it can float on water).
High Energy Absorption: Upon impact, its porous structure effectively absorbs energy by collapsing layer by layer, resulting in exceptionally high and stable performance.
Heat Resistance & Non-Flammability: Made from aluminum, it offers extremely high heat resistance and will not burn.
Electromagnetic Shielding: It provides excellent electromagnetic interference (EMI) shielding.
Sound Absorption and Insulation: Its porous structure offers excellent acoustic properties.
- Key Applications:
This product partially overlaps with JSP’s EPP applications, but offers higher-end performance and is used in more demanding environments:
Construction: Used as a core material for fire-resistant partition walls and fire-resistant doors in high-end buildings. In the event of a fire, it does not burn, effectively blocking flames and heat.
Transportation:
Railway: Used as an impact energy-absorbing structure (crash pad) for locomotives.
Marine: Used in fireproof partition walls on luxury cruise ships and other equipment.
Industrial Equipment: Used as crash barriers for factory automation equipment and safety materials for robotic arms.
Military and Aerospace: Used in specialized structures requiring lightweight and high energy absorption (due to its high cost, it is mostly used in high-end applications).
7. DS Smith (UK)
Headquarters: London, UK
Founded: 1940
Key Products: Sustainable EPP packaging, automotive components
DS Smith’s business is a highly integrated circular system, primarily organized into the following areas:
- Packaging Production
This is its core business. They produce a wide range of paper-based packaging:
Corrugated cardboard boxes: This is their primary product, used for shipping and e-commerce packaging across a wide range of industries.
Carboard: Retail boxes for high-end consumer goods, cosmetics, electronics, and more.
Innovative Packaging Solutions: They offer customized designs, such as:
E-commerce Solutions: Break-resistant, easy-to-open, and recyclable e-commerce boxes.
Retail-ready packaging: Product packaging can be removed directly from shipping boxes and put on shelves, saving time and costs.
Fresh packaging: Packaging for fruits, vegetables, and other perishable foods.
- Paper Recycling
DS Smith is one of Europe’s largest paper and cardboard recyclers.
They collect, sort, and process millions of tons of waste paper and cardboard annually.
This recycled fiber is the core raw material for their packaging production and forms the foundation of their circular economy model.
- Paper Production
We operate our own paper mill, using recycled fiber to produce recycled corrugated cardboard.
This ensures a secure supply of raw materials for our packaging products and controls quality and costs.
- Plastic Replacement
This is a key strategic direction for DS Smith. We use paper-based solutions to help customers replace single-use plastics in their supply chains. For example:
Replacing plastic fruit and vegetable trays in supermarkets with cardboard.
Replacing plastic foam filling with paper cushioning.
Developing recyclable paper packaging to replace blister packs.
8. Kaneka Corporation (Japan)
Headquarters: Osaka, Japan
Founded: 1949
Key Products: EPP beads, specialty foams
Kaneka’s business is highly diverse, but its core lies in applying chemical technology to solve specific challenges. These businesses are primarily divided into the following segments:
- Functional Polymers
This is Kaneka’s core and traditional strength, most closely related to packaging materials.
Foamed Plastics:
Kaneka Polymeric Foam (KPF®): This is Kaneka’s proprietary modified PPE (polyphenylene ether) foam. It is a high-performance engineering foam with excellent heat resistance, flame retardancy, low smoke toxicity, and high stiffness. It is widely used in interior panels, core materials, and insulation materials for aerospace, rail transit (high-speed rail), and ships, making it a star product in the high-end market.
Foamed Polyolefins: The company produces cross-linked polyethylene (IXPE) and polypropylene (IXPP) foams for automotive interiors, sporting goods, construction mats, and packaging.
Polymer Modifiers:
MS Polymers: Silane-modified polyether-based resins used in the production of environmentally friendly sealants, adhesives, and coatings that are isocyanate- and solvent-free.
PVC processing aids and impact modifiers: Improve the processing properties and impact resistance of polyvinyl chloride (PVC), and are widely used in building materials (such as door and window profiles and pipes).
- Chemicals
Organic Chemicals: Produce basic chemical raw materials and intermediates.
Specialty Chemicals: Include polyvinyl butyral (PVB) film used for photovoltaic module encapsulation.
- Food & Nutrition
Health Foods: The most well-known product is red yeast rice-related health foods, which claim to help maintain healthy cholesterol levels.
Probiotics: Develop and produce probiotic strains and raw materials.
Food Additives: Products such as xanthan gum.
- Life Sciences
Pharmaceuticals: Research and develop cardiovascular drugs and anti-infective drugs in the treatment and treatment fields.
Medical Devices: Produce interventional medical devices such as balloon catheters used in cardiovascular surgery, a very important high-growth business.
- Electronic Materials
Optoelectronic Materials: Produces flexible substrate films and optical films for OLED displays.
Semiconductor Materials: Provides key materials used in semiconductor manufacturing, such as CMP polishing pads.
9. Borealis AG (Austria)
Headquarters: Vienna, Austria
Founded: 1994
Key Products: Sustainable EPP for automotive and construction
Borealis’s business is organized into two main segments, forming a highly integrated value chain:
- Basic Chemicals (Hydrocarbons & Energy)
Role: Provides key raw materials for its own plastics production.
Business: Acquires basic chemicals such as ethylene and propylene from partners (such as parent company OMV and ADNOC) or produces them in-house. These are the “building blocks” for all plastics.
- Polyolefins
This is the heart and soul of Borealis. These basic chemicals are polymerized to produce various grades:
Polyethylene (PE): The world’s most produced plastic, used to make films, plastic bags, containers, pipes, cable sheathing, and more.
Polypropylene (PP): An extremely versatile plastic used in automotive parts, home appliances, packaging, piping, textiles (nonwovens), and more.
Innovative and High-Performance Products:
Borstar® Technology: Borealis’s flagship bimodal technology produces polyethylene and polypropylene products with exceptional strength, processability, and durability. For example, it is used to create thinner, stronger packaging films, more pressure-resistant piping systems, and high-performance capacitor films.
Queo™: A high-performance specialty polyolefin used in flexible packaging, adhesives, and automotive applications.
- Circular Economy Solutions
Borcycle™: This is Borealis’ brand for advanced mechanical and chemical recycling technologies that convert waste plastics into recycled plastic feedstock.
Renewable Polyolefins: Plastics made from renewable hydrocarbons produced from bio-based feedstocks, such as waste cooking oil, reduce dependence on fossil fuels.
10. Dongshin Industry Inc. (South Korea)
Headquarters: Seoul, South Korea
Founded: 1978
Key Products: EPP automotive parts, industrial foams
Dongshin Industry is highly specialized in a key subsystem within automotive seating systems. Its main products include:
Seat Adjustment Mechanisms
Seat Slides: These allow the seat to move forward and backward, making them one of the most fundamental and core components of a seat. They are Dongshin’s core products.
Recliners: These devices control the fore-and-aft adjustment of the seatback, crucial for comfort and safety.
Height Adjusters (Lifters): These adjust the vertical height of the seat.
Lumbar Support Adjusters: These provide lumbar support adjustments.
Complete Seat Frames
The various adjustment mechanisms mentioned above are integrated into a complete metal frame structure, forming the seat’s “framework.” This frame is then equipped with foam padding, trim, airbags, and other components to create a complete automotive seat.
Other Related Components
We manufacture other metal stampings and assembly parts related to seating systems.
How to Choose Best Expanded Polypropylene?
Choosing the best Expanded Polypropylene (EPP) foam depends on your specific application requirements. Here are the key factors to consider when selecting EPP foam:
1. Density (Weight & Strength)
- Low Density (20-50 g/L): Lightweight, good for packaging and cushioning.
- Medium Density (50-100 g/L): Balanced strength and flexibility, used in automotive parts and sports gear.
- High Density (100-250 g/L): High impact resistance, suitable for structural components.
2. Cell Structure (Open vs. Closed Cell)
- Closed-Cell EPP: Better energy absorption, moisture resistance, and buoyancy (ideal for automotive and marine uses).
- Open-Cell EPP: More breathable, used in filtration and acoustic insulation.
3. Impact Resistance & Energy Absorption
- For protective packaging (e.g., electronics), choose EPP with high shock absorption.
- For automotive safety (e.g., bumpers), select high-density EPP with excellent rebound properties.
4. Temperature Resistance
- Standard EPP works in -30°C to 130°C (-22°F to 266°F).
- For extreme conditions (e.g., aerospace or industrial insulation), verify thermal stability.
5. Chemical & Environmental Resistance
- Resistant to oils, acids, and water—ideal for marine, medical, and automotive uses.
- UV-resistant grades are needed for outdoor applications.
6. Customizability (Shape & Color)
- EPP can be molded into complex shapes (e.g., custom packaging inserts, car seats).
- Available in various colors for branding or functional differentiation.
7. Recyclability & Sustainability
- Choose 100% recyclable EPP if eco-friendliness is a priority (better than EPS/Styrofoam).
- Some manufacturers offer bio-based EPP for reduced carbon footprint.
8. Cost vs. Performance
- Higher density = more expensive but better durability.
- Compare with alternatives like EPS (Styrofoam) or PU foam—EPP is costlier but lasts longer.
Best EPP Foam for Common Uses:
| Application | Recommended EPP Type |
|---|---|
| Protective Packaging | Low-to-medium density (30-70 g/L), closed-cell |
| Automotive Parts | Medium-to-high density (70-150 g/L), high impact resistance |
| Sports & Helmets | Medium density (50-100 g/L), good rebound |
| Thermal Insulation | Closed-cell, medium density |
| Marine & Buoyancy Aids | Closed-cell, waterproof |
Conclusion
The EPP industry is dominated by JSP, Epsole, and Knauf, with strong competition from Asian manufacturers like Hanwha and Kaneka.
Sustainability, automotive innovation, and smart packaging are key drivers in 2025.
For businesses seeking high-performance EPP solutions, these top 10 manufacturers offer the best in technology, reliability, and eco-friendly materials.