Rethinking best practice
When EXPOL founder Terry Mischefski launched his company in Auckland in 1978, he couldn’t have imagined how far it would grow. What began with a hot-wire polystyrene cutting method to make cost-effective packaging soon evolved into a nationwide enterprise producing high-quality insulation. Today, EXPOL is New Zealand’s largest polystyrene manufacturer and recycler – still 100 per cent family-owned and operated.
Now, the company is marking another major milestone: the construction of a new South Island factory in Rolleston’s iPort industrial business hub – a significant investment that strengthens EXPOL’s national production and distribution network.
To bring the project to life, EXPOL partnered with Carbon Property, an expert in property development. “We manage all facets of the pre-project planning right through to hand over,” says Ben Lagan, Managing Director of Carbon Property. “We set up the contractual arrangements, guide property decisions, and ensure everything is aligned for the operating business. It’s about delivering a platform for Terry’s business to walk straight into while also refining his property investment outcome, too.”
This move will also support new jobs in the Canterbury community. “It’s a huge investment in the business but also in our region” says Ben. “This is a major vote of confidence for a NZ-owned, family-run business of this size to double down on this type of facility in the South Island. It shows that NZ still has what it takes to be competitive against off-shore production.”
Producing EXPOL’s polystyrene products requires a steady supply of steam. The process starts by expanding polystyrene beads, then moulding and cutting them into the familiar insulation shapes used across the country. Traditionally, such operations rely on diesel or LPG boilers, but EXPOL has taken a more sustainable route.
“This site uses a 2.75MW biomass wood pellet boiler,” Ben explains. “It certainly wasn’t the cheapest option for Terry, but it made sense to turn away from fossil fuel-based boilers.” With the uncertainty of future gas supply and consistent increases in electricity pricing, it ensures EXPOL’s future remains reliable and cost-effective. “It’s a big deal and an absolute necessity for long-term production.”
The investment extends beyond the boiler. EXPOL has also acquired some of the most advanced moulding, shaping, and cutting technology available. “Terry did his homework to find the best manufacturers,” says Ben. “It’s all about future-proofing – not just the equipment, but the entire business.”
That future-focused approach aligns with Carbon Property’s philosophy. “We spent almost a year with Terry testing feasibility – expanding and contracting the building footprint, assessing what was truly best practice. We’re merging business efficiency with property development efficiency right from the start.” EXPOL backs this up operationally. They run one of the country’s largest polystyrene recovery and recycling operations – showing a real commitment to all parts of their product’s lifecycle.
For Carbon Property, Rolleston’s iPort is an ideal setting for developments like this. “The new motorway has been a game changer,” Ben says. “It connects iPort and Rolleston to the city, putting it on par with any industrial location in Christchurch.”
Construction of the new EXPOL facility is scheduled for completion in April 2026, with commissioning and fit-out to follow shortly after. Once operational, the production facility will stand as a model of sustainable investment.