Mainfreight Sets New Environmental Benchmark in New Zealand's Terminal Distribution Sector with Polystyrene Compactors

Mainfreight, a leading publicly listed transportation company in New Zealand, is taking significant steps toward environmental sustainability by integrating Polystyrene compactors into its operations. The move positions the company as a green leader in the country’s terminal distribution industry.

Mainfreight operates across international shipping, land transportation, and warehousing, with a workforce of over 2,000 employees worldwide—approximately half of whom are based in New Zealand. The company currently runs 27 transfer stations throughout the country, including 12 on the North Island and 15 on the South Island.

One of Mainfreight’s core services is home delivery (Home Delivery) of large household appliances. It partners with major appliance brands such as Samsung, Farmers, and Fisher & Paykel to handle final-mile delivery. This includes collecting appliances from the brand's warehouse, delivering them to customers, and recycling packaging materials like cardboard and EPS (Expanded Polystyrene) foam.

Mainfreight's recycling centers accumulate around one pallet of loose EPS and cardboard waste every 2–3 days. These materials are bulky, take up valuable space, and are costly to dispose of through third-party services. This created an urgent need for a more efficient, cost-effective recycling solution.

After conducting market research and receiving positive feedback from other companies, Mainfreight reached out to INTCO Recycling, a global leader in EPS recycling with decades of experience. INTCO designs and manufactures Polystyrene compactors under its machinery brand GREENMAX, and also processes compressed waste into plastic pellets and framing products.The collaboration aimed to provide Mainfreight with a comprehensive recycling solution—from equipment supply to end-material repurposing.

Customer Feedback on GREENMAX Polystyrene Compactor

• After installing the GREENMAX Polystyrene Compactor A-C100, Mainfreight reported highly positive outcomes:
• User-Friendly Operation: Equipment operators noted the machine runs smoothly and is easy to use, even for first-timers.
• Space Efficiency: The compactor significantly reduced the volume of loose packaging. One pallet’s worth of loose EPS can now be compressed into dense blocks weighing 100–200 kg, dramatically improving storage utilization.
• Cost Savings & Revenue Generation: The compacted materials not only reduce waste disposal costs but can also be sold, creating a new revenue stream.

Positive Impact and Future Plans

• By adopting GREENMAX’s compactor, Mainfreight has:
• Solved key operational challenges associated with packaging waste
• Improved warehouse efficiency
• Achieved notable cost and environmental benefits

Encouraged by the results, Mainfreight plans to expand the use of Polystyrene compactors across more locations, and hopes to inspire other companies in related industries to join the recycling movement.