EPS Manufacturing | Complete Dryer Screen System Replacement

Client: Huntsman Chemical
Application: Dewatering and drying wet EPS beads after reactor processing
Industry: EPS Manufacturing

In EPS (expandable polystyrene) manufacturing, wet EPS beads must be dewatered and dried after reactor processing. Many plants use Carter Day centrifugal dryers where beads spiral upward on rotating paddles while warm air flows counter-current and moisture exits with the air through a large conical screen.

ActionLaser worked with Huntsman Chemical on a solution that;

• Solves four key wedge wire problems
• Has flexible 280 micron laser screens
• A Complete sealing system with no silicone required
• Faster cleaning and reduced downtime
• Higher open area increasing dryer capacity
• Proven globally across EPS grades

Huntsman Chemical experienced persistent issues with the existing wedge wire dryer screens used to retain the EPS beads. Wedge wire panels are heavy and rigid, difficult to install, and do not conform well to the hoop supports, creating gaps that leak fine beads. Operators relied on silicone sealant to plug leaks, but the sealant complicates frequent cleaning requirements: sticky catalyst residues routinely clog screens, forcing regular water jetting and weekly demount-and-clean routines. Wedge wire also offers a relatively low open area, limiting airflow and constraining dryer capacity.

Huntsman approached ActionLaser to design a complete replacement screen system to solve handling, fitment, bead loss, and capacity constraints. ActionLaser developed flexible laser-drilled screens with 280 micron holes, produced in two segments (instead of three for wedge wire), enabling easier handling. A tongue-and-groove seal prevents bead loss at the join, while a continuous edge-band seal with rubber backing and an internal silicone rubber seal creates a reliable circumferential seal, eliminating the need for silicone sealant.

The system was installed at Huntsman’s Peru, Illinois facility and performed immediately: installation was faster and simpler; sealing was reliable without sealant; weekly demounting became dramatically faster; and cleaning was easier because screens could be laid flat for water blasting. Most importantly, the higher open area of the LaserScreens improved airflow, shifting the throughput-versus-dryness balance.

The improvement came from addressing multiple wedge wire limitations at once rather than treating them in isolation. Handling difficulty, poor fitment, bead leakage and restricted drying capacity were all removed as system constraints.

Laser-drilled screens at 280 microns matched the proven retention size while being lighter and easier to install. Improved fit, reduced handling risk and simplified routine maintenance.

A fully engineered sealing approach eliminated bead loss without relying on silicone. Tongue-and-groove joints, edge-band sealing and internal seals maintained containment through repeated operation and cleaning.

Higher open area increased airflow through the dryer, lifting throughput without compromising bead drying. Faster cleaning and reduced downtime improved operational rhythm, supporting adoption across multiple sites and EPS grades.

The plant achieved higher throughput while maintaining the required bead dryness, delivering a strong productivity and cost outcome. Huntsman subsequently implemented the system across multiple global EPS sites, and the solution proved effective in both standard EPS grades and fine “cup-grade” bead production.