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When it comes to recycling, we assign numbers to the materials we recycle. Like soda and water bottles, they fall under number 1. Laundry detergent and other containers are classified under number 2. Meanwhile, plastic bags fall under number 4. But let’s not forget about foam #6, which encompasses a variety of items such as packaging material for electronics and furniture, food trays and containers, foam cups, egg cartons, foam peanuts, and medical coolers. All of these are made of that infamous material known as Styrofoam. You might also hear it referred to as polystyrene, expanded polystyrene, or EPS foam.

Polystyrene happens to be one of the most prevalent forms of plastic. It’s a mixture that consists of a whopping 98% air and only 2% polystyrene. Not only is it resistant to water and heat, but it also serves as an excellent insulator. Due to its immense popularity, the global demand for EPS and its production is on the rise, which is why we’re in dire need of recycling methods.

Now, while we can reuse foam peanuts by recycling, all the other EPS materials require a recycling process that reduces their volume. To recycle them, we meticulously inspect the material and remove any contaminants. Then, we feed the foam into recycling machines, either for cold compaction or thermal densification. Cold compaction allows for volume reduction using a compactor, no heat required. What we end up with are dense logs or bricks that occupy only 2% of their original volume. The thermal method, on the other hand, involves feeding the foam into a densifier machine. Utilizing heat and friction, the densifier melts the foam. Once melted, the machine uses pressure to push the material through a small opening, resulting in long, slender strands. These strands are then cooled and cut into pellets, facilitating transportation. The recycled foam is then sent to other manufacturers, who use it to create new plastic products.

Recycled foam Number 6 proves to be a valuable resource for producing new cost-effective materials and products. Take picture frames, pens, and office supplies, for example. We can also fashion clothes hangers, curtain rods, and outdoor furniture out of it. CD cases, toys, and pony packs for growing and transporting seeds and plants can also be crafted from this material. Plus, it’s ideal for constructing interior and exterior architectural moldings, ornamental home décor, and SIPS (Structural Insulated Panels). Furthermore, we can mix recycled EPS with wood or concrete, creating efficient building insulation that is resistant to water, mold, and decay. Alternatively, it can be transformed into additional foam packaging material.

The benefits of using recyclable foam instead of the original raw material to manufacture new products are numerous. It conserves natural resources, reduces littering and pollution, saves landfill space, and requires less energy. Manufacturers, on the other hand, find recycled foam to be of great value and are willing to pay handsomely for it. In recent years, recycling foam has become easier and more efficient thanks to technological advancements. Recycling equipment can now reduce the volume of foam by up to 95% of its original size and requires significantly less labor. Ultimately, recycling leads to a reduction in landfills and fosters a more sustainable environment for all of us.

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Ihab Salloum