GREENMAX Polyethylene Foam Melting Machine/ Densifier

Polyethylene foam (PE foam) is a versatile material widely used across industries such as packaging, construction, automotive, electronics, logistics, sports equipment, and home appliances. Known for its durability, cushioning performance, and thermal‑insulation properties, PE foam is also 100% recyclable, making it an increasingly preferred choice for companies seeking sustainable and cost‑effective packaging solutions.

As an eco‑friendly alternative to traditional packaging materials, PE foam can be reused, repurposed, or melted into granules for manufacturing new products. A polyethylene foam melting machine significantly improves the recycling process, helping businesses reduce waste, lower disposal costs, and support environmental protection and resource conservation.

PE Foam Recycling with Hot Melting Densifier

Loose and bulky waste PE foam takes up significant storage space and is costly to transport in its original form. A hot melting densifier solves this problem by melting the foam into compact, high‑density blocks. This process dramatically reduces the volume of polyethylene foam, making handling, storage, and transportation far more efficient. The resulting dense blocks are easier to ship and can be reused or further processed, making hot melting densifiers an effective solution for improving PE foam recycling and overall waste‑management efficiency.

GREENMAX PE Foam Hot Melting Densifier

GREENMAX Mars series hot melting densifier is a specialized recycling machine engineered specifically for rigid polyethylene foam. Using controlled heat, it melts and densifies PE foam into uniform, manageable blocks. This technology not only streamlines recycling operations but also transforms waste foam into valuable, reusable resources that can be re‑granulated and used in new plastic products. INTCO Recycling also buys back recycled PE foam blocks and processes them for further recycling and reuse. With its reliable performance and high efficiency, GREENMAX Mars series is widely adopted in industries that generate large volumes of PE foam waste.

PE Foam Densifier Operation Process:

1. double shredding blades will smash waste polyethylene into scatters.
2. the machine screw will be heated and scattered polyethylene foam will be melted as well.
3. melted polyethylene foam will be extruded from the slot with machine screw rotation. So scattered waste polyethylene foam is melted down into blocks after cooling.

PE Foam Densifier Advantages:

Melted polyethylene foam is more clean and more tidy.
Compared to foam recycling compactor, not easy to get scattered.
Have been sold to countries worldwide with proven and successful cases.

Successful Case:

CASE 1: Wheel Hubs Manufacturer and PE Foam Recycling

Prime Wheel is the largest manufacturer of automotive wheel hubs in North America. There are 3 factories in all in the United States and Mexico. In the production and transportation of wheel hubs, the use of Polyethylene(PE Foam) is very common, and almost necessary, to protect the wheels from being damaged. However, the disposal of the polyethylene sheet and roll after use is very difficult, even if by landfill, it also needs to spend a lot of labor for sorting. Prime Wheel has been no suitable method for polyethylene recycling until they found GREENMAX, a specialist devoted to foam recycling.

Recently, Prime Wheel successfully installed GREENMAX foam densifier M-C200. Characterized in easy operation, labor-saving, and higher efficiency, such a machine has so far been running for hundreds of hours, compressing at least 200,000 pounds of waste polyethylene, which is not only the storage space, but the transportation cost can be largely saved.

CASE 2:  Electronics Manufacturer and PE Foam Recycling

Quanta Computer is the largest notebook computer R&D, design, and manufacturing enterprise in the world, which has two Data Rack manufacturing bases in Tennessee and California, USA. During the manufacturing process, it generates about 4000 lbs of waste for 2 trucks per day. Previously, Quanta has been handing over the PE packaging materials by giving them to the local recycler, but the bankrupt of the recycler make Quanta Computer have to pay nearly $7000 for waste management.

In order to save high operating costs, Quanta began to seek professional PE foam recycling equipment and chose GREENMAX because of its reputation. They purchased a GREENMAX PE foam densifier M-C200 to dispose of their own PE foam packaging waste. After half a year of operation, there are more than 250,000 lbs of PE foam waste has been recycled, which has saved more than $42,000 in landfill fees and greatly increased the efficiency of plant operation.

Polyethylene Foam Densifier:

PE Foam Densifier MARS C100
Throughput 100kg/h
EPE Compression Ratio: 90:1
Compressed EPE Density: 600-800kg/m3
Motor Power: 22.9kw

PE Foam Densifier MARS C200
Throughput 200kg/h
EPE Compression Ratio: 90:1
Compressed EPE Density: 600-800kg/m3
Motor Power: 37.5kw

PE Foam Densifier MARS C300
Throughput 300kg/h
EPE Compression Ratio: 90:1
Compressed EPE Density: 600-800kg/m3
Motor Power: 37.5kw

GREENMAX PE Foam Melting Machine Video:

GREENMAX Auto Smart System For Foam Melting Video: