One Machine, Two Applications: GreenMax Foam Densifier Easily Handles Both EPS and EPE Recycling

Today, with plastic packaging widely used across industries, companies often generate two common types of waste during production and logistics: EPS (expanded polystyrene / Styrofoam) and EPE (expanded polyethylene).

Both materials are bulky, lightweight, difficult to transport, and environmentally unfriendly to landfill—making them major challenges for many factories and distribution centers.

 

Traditional cold-press compactors can only handle Styrofoam. However, elastic EPE tends to rebound and expand after compression, preventing it from achieving the desired volume reduction.

To solve this problem, GreenMax has developed a customized foam densifier using high-temperature thermal melting technology. It efficiently processes both EPS and EPE, offering a true “two-in-one” solution that helps companies save on equipment costs.

Below is the test run video recorded before shipment. As shown, both types of foam waste are successfully compacted into dense blocks with up to a 90:1 volume reduction, demonstrating the machine’s impressive recycling performance.

EPS recycling Process Overview

This foam recycling system consists of a conveyor, foam crusher, storage silo, screw feeder, standard densifier, and electrical control cabinet.

During the EPS recycling process, the workflow is as follows:

Conveyor → Foam Crusher → Silo → Screw Feeder → Standard Densifier

Below is a step-by-step explanation:

  1. Conveyor Feeding: EPS waste is transported into the crusher.

  2. Crushing: The crusher breaks the EPS into uniform pieces.

  3. Air Conveying & Storage: The crushed material is blown through pipes into the silo for temporary storage.

  4. Screw Feeding: The screw feeder continuously and steadily delivers EPS pieces from the silo into the densifier.

  5. Thermal Compression: Inside the densifier, the EPS is heated, melted, and compressed, achieving up to a 90:1 volume reduction.

A dedicated connection between the densifier and the screw feeder ensures smooth and efficient material flow throughout the process.

EPE recycling Process Overview

The EPE recycling process is mainly completed in the standard densifier. This machine combines crushing and compacting in one unit, allowing EPE foam to be fed directly into the system, where it is automatically shredded, melted, and extruded into solid blocks—compressed down to 1/90 of its original volume.

Two separate recycling lines handle Styrofoam (EPS) and EPE independently, preventing material mixing and ensuring high-purity, high-quality recycled blocks. The densifier is also equipped with a frequency converter, allowing operators to adjust the melting rate for each type of foam to achieve optimal processing conditions.

For facilities with a larger volume of EPE waste, the two lines can be adjusted or switched as needed to improve throughput and maximize resource efficiency.

Why Can GreenMax Foam Densifier Handle Two Materials in One Machine?

First, the GreenMax foam densifier uses a thermal densification process that works with multiple foam materials—including EPE, EPP, and EPS—making it inherently capable of processing both Styrofoam and expanded polyethylene in the same system.

Second, because these foams differ in density and size, the crushing and heating requirements also vary. To ensure optimal performance, each recycling line is equipped with custom-built crusher blades, designed by GreenMax based on the customer’s waste characteristics for the best shredding results.

Most importantly, the melting temperature, screw speed, and other thermal parameters directly affect block density and molding quality. Leveraging years of experience, GreenMax engineers have pre-programmed the ideal settings for both EPS recycling and EPE recycling into the control system, allowing users to switch modes with just one click.

Lastly, GreenMax configures two independent recycling lines based on the customer’s waste volume ratio:

 • The larger amount of Styrofoam is fed by conveyor into a silo for centralized processing.

 • Smaller quantities of PE foam can be fed directly into the machine for shredding and densifying.

This dual-line design prevents material mixing while significantly improving overall recycling efficiency and equipment utilization.

GreenMax — making EPS recycling and EPE recycling simpler, more efficient, and more sustainable.

One machine, multiple benefits — turning foam recycling into an easy, streamlined process!