#foamcompactor

With a GreenMax foam compactor, EPE, EPP, and EPS packaging waste is processed directly on site.

The results:

✅ Replaced an old machine ✅ Improved labor efficiency by 4x ✅ Only one operator needed for the line ✅ More stable processing for different foam materials ✅ Fast on-site support from GreenMax

Bulky packaging waste is turned into a more marketable recycling material.

And the best part? The customer is even open to on-site visits for European prospects. 👀

Foam recycling doesn’t have to be complicated. With the right machine, a space problem can become a valuable resource. ♻️

Battery trays, inserts, returnable boxes… they protect parts during transport, but after unpacking, they quickly turn into a warehouse space problem. 📦

The real issue is not weight. It is volume.

💡 That is why more manufacturers are choosing to densify first, instead of shipping waste out loose.

An EPP foam densifier can turn bulky foam waste into compact blocks with up to 50:1 reduction, making storage easier, freight cheaper, and recycling more practical. ♻️

In simple terms: less air shipped, more value moved.

With tighter recycling requirements ahead, early EPP recycling planning matters more than ever.

Appliance retailers generate large amounts of EPS packaging waste through return centers and customer unpacking. This bulky foam takes up storage space and increases hauling and disposal costs. ♻️

In 2024, Clayton Appliances, Inc. in Georgia installed the GREENMAX polystyrene densifier M-C200 to reduce the volume of waste unicel packaging and move it into the recycling stream instead of landfill. GreenMax also supported the customer through an EPS block buyback program to help improve the return on equipment investment.

Where EPP scrap typically comes from:

Production offcuts/trim (cutting, trimming, assembly)

Retired returnable packaging (worn, redesigned, end-of-life inserts/cushions)

Defects and rework parts

✅ Cleaner, single-material scrap is easier for EPP recycling. Tape/film/dust/oil contamination quickly drives up handling cost.

Why total handling costs run high: it’s mainly volume, not weight—foam fills scrap areas, increases internal handling, trucks fill up faster (more pickups), and loose foam is harder for recyclers to accept.

Fastest win: on-site compaction/densification Using an EPP foam compactor / foam recycling machine turns loose foam into a more controlled form: ✅ Less floor space | ✅ Fewer hauls | ✅ Cleaner scrap area | ✅ Smoother recycler handoff

GreenMax can match an EPP foam compactor setup to your scrap form and throughput—without disrupting production—so your EPP recycling stream becomes more stable. ♻️

EPS offcuts are bulky and low-density, taking up space and increasing disposal costs. More cutters are exploring Styrofoam recycling, but before investing in a foam compactor, consider three key questions:

1️⃣ Monthly EPS waste:

Small shops: A-C50; future growth: A-C100

Mid-sized: A-C100 / A-C200 for stable operation

Large centers: A-C300 for high-volume, one-step compression

2️⃣ Facility space & power:

A-C50 fits in a corner (~1.5 boxes)

A-C100 <11 kW, works with standard industrial power

Apolo series uses screw compression, no heating, low energy

3️⃣ Waste reduction or reuse?

Waste only: Compress 50:1 into high-density blocks, easy to store and sell

Reuse planned: Consider direct pelletizing to avoid extra steps

GreenMax helps plan from volume reduction to material reuse. Recycling EPS saves space, reduces costs, and improves efficiency. 🌱

Latest Styrofoam Recycling Technology - Physical compaction with a 50:1 ratio