In less than a decade since its establishment, Al Sharq Factory for Polystyrene (StayroMax) says it has become one of the largest manufacturers of its kind in the Kingdom.

It is also playing a key role in the region's development towards self-sufficieny of such products, it adds.

The company, which was established in 1995, has a 68,000 sq m factory in Dammam, with a production capacity of 7,200 tonnes a year. It produces a range of high-quality products under the StayroMax brand such as  thermal roof panels and wall panels, block inserts,  decoration items for masonry works, hourdi blocks for ceilings, industrial packaging and pipe insulation.

It has a well-equipped quality control department with modern measuring and analytical instruments as well as qualified, trained and experienced staff.
''Every raw material and finished product is methodically tested and analysed in our laboratory to confirm that they meet specified quality standards,'' says a company spokesman. ''Continuous chemical and physical analysis is conducted during production to ensure stability of specifications and a certificate of analysis is issued to accompany customers' outgoing shipments.''

Al Sharq also owns a huge fleet of vehicles specially designed to transfer the polystyrene products  throughout the GCC.

Commenting on the need for thermal insulation, the spokesman says: ''Increasing energy costs show there is an urgent need for energy conservation, even in the oil-producing countries. An effective way of saving energy is to improve the thermal insulation of buildings. This is particularly important in hot climates where the energy demand for cooling by air-conditioning is very high. In addition to the need for energy saving, high insulation standards are justified by improved comfort levels and increased building life.'' 

Elaborating on the role of polystyrene in insulation, he continues: ''Polystyrene products play a major role in energy conservation. There are two types of polystyrene manufactured: expanded (moulded) polystyrene (EPS) and extruded polystyrene (XPS).
''EPS is a moulded, closed cell/cellular plastic made from petrochemicals derived from crude oil. EPS is a unique material, having excellent insulating qualities. A lightweight, strong and resilient, non-corrosive, dimensionally stable material, EPS is moulded into blocks and is available in many different densities and thicknesses. EPS foam used as thermal insulation reduces harmful air emissions by saving resources and energy which would be consumed due to greater heating and air-conditioning requirements.

''EPS is an efficient and effective thermal insulation material. No CFCs (chlorofluorocarbons)or HCFCs (hydrochlorofluorocarbons) are used in its manufacture; it is non-toxic and inert so EPS causes no known damage to the ozone layer. EPS used in construction will consistently continue to save energy throughout the life of the building.''
Al Sharq's factory produces insulating sheets in densities ranging between 16 kg /cu m to 35 kg /cu m which can be cut into different sizes and thickness.

With the help of computerised cutting machinery, it can manufacture various decorative shapes and forms such as arches, stoops, partitions, circles and domes according to engineering drawings. It can also mould industrial packaging for air-conditioners, refrigerators, electrical  and electronic household appliances (television and  audio systems) and glass, which protect them against damage during handling and transportation. EPS is shock-proof and does lose its shape or insulating value with age.

Extruded polystyrene (XPS) is manufactured by a continuous extrusion process, which imparts a characteristic closed cell structure giving the product its unique physical properties.

XPS rigid foam has a high resistance to water absorption and good mechanical properties. The manufacturing process, combined with the inherent qualities of the inert component thermo-plastic material gives XPS predictable long-term performance and high insulating value, the spokesman adds.