Case Study

Zacharioudakis GmbH partnered with JSP to produce one of the largest single-piece expanded polypropylene (EPP) transport containers using white ARPRO. This solution demonstrates the potential of high-density EPP to deliver precise, large-scale formats for industrial logistics, where durability, protection, and sustainability are essential.

Problem

Design and mould a very large, single-piece EPP transport container to be used in airport systems. The container had to meet strict mechanical and dimensional requirements: consistent high density, minimal shrinkage, excellent surface finish, and structural integrity throughout. As it would be reused in transit environments, durability and recyclability were also essential.

Solution

JSP supplied a high-density white ARPRO grade (moulded at 130 g/l), selected for its outstanding mechanical performance, precision moulding capability, and clean aesthetic. The complex large-format moulding process achieved consistent geometry and high surface quality across the oversized component.

The result was a durable, lightweight transport container suitable for repeated use in airport logistics — a functional alternative to traditional multi-part systems. This project sets a new benchmark for scale in EPP moulding and highlights ARPRO’s suitability for demanding, high-volume applications.

Key Features and Benefits of White ARPRO

Large-Scale Moulding Capability
 • Enables production of oversized, high-precision transport units
 • Maintains structure and density evenly across large volumes
 • Eliminates the need for segmentation or assembly

Dimensional Accuracy and Low Shrinkage
 • Typical shrinkage between 1.8% and 2.2%, even at large sizes
 • Predictable behaviour supports tight tolerances and reliable fit
 • Smooth, uniform finish improves appearance and function

Mechanical Strength and Lightweight Performance
 • Compressive strength ~300 kPa at 50% strain
 • Tensile strength ~550 kPa with ~19% elongation
 • Protects contents from impact and stacking stresses

Thermal, Acoustic, and Chemical Properties
 • Thermal insulation suitable for sensitive goods
 • Acoustic damping properties for quieter transport systems
 • Chemically inert and resistant to moisture, oils, and greases

Clean Aesthetic and Functional Colour
 • White ARPRO provides a neutral, hygienic appearance
 • Ideal for airport, logistics, or brand-critical applications
 • Compatible with printing, surface coatings, and decorative finishes

Sustainable and Efficient
 • 100% recyclable material
 • Reusable format reduces waste and carbon emissions
 • Efficient to process with minimal production loss

The size of the container made this project especially challenging and rewarding. With moulding precision and the reliability of white ARPRO, we were able to achieve consistent results at scale. This project pushes the boundaries of what’s possible with EPP.”

Michele Rizza, Zacharioudakis GmbH