The invention relates to a forming process and 
system for manufacturing packaging 
expanded polystyrene. The process comprises the steps of (1) first-stage expansion, (2) second-stage expansion, (3) material feeding, (4) three-stage expansion, (5) 
thermal insulation, (6) primary cooling, (7) secondary cooling, (8) final cooling and (9) mould removing. The 
system comprises a first-stage expansion 
machine, a second-stage expansion 
machine, an 
expanded polystyrene forming 
machine, a water bin used for the primary cooling, a 
drying purifier for the secondary cooling, a negative pressure cooling device for the final cooling, and a boiler used for generating 
water vapor. According to the process and the 
system, two purposes can be realized by one system, so that the cost of production and manufacturing can be lowered; water in the packaging 
expanded polystyrene can be dried by 
thermal insulation, so that the forming quality is improved; the 
water cooling and the negative pressure cooling are combined, so that the cooling of a mould is accelerated, the 
processing and manufacturing period is shortened, and the production efficiency is improved; the cooling of the mould is divided into three stages, the phenomena of holes, and incompleteness and irregular deformation of the packaging expanded 
polystyrene caused by abrupt 
temperature drop can be avoided, so that the forming quality of the packaging expanded 
polystyrene can be effectively improved.