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GREENMAX Styrofoam Densifier Hot Melting Machine
Expanded Polystyrene (EPS, also known as Styrofoam or Foam #6) is widely used for thermal insulation and protective packaging during transportation. It is essential in home appliance delivery and fragile goods logistics to prevent damage. EPS materials are commonly generated in daily operations, including furniture packaging, construction applications, and post-consumer foam waste streams.
In Europe and North America, EPS recycling has improved in recent years, with overall recycling rates reaching around 30% in North America and about 40% in Europe. However, a large portion of EPS waste—especially from construction and household sources—still ends up in landfills or incineration due to high transportation costs and inefficient collection systems.
Styrofoam Recycling Solution by Styrofoam Densifier
A Styrofoam densifier efficiently recycles waste EPS by first crushing it into small, manageable pieces, then processing it through an advanced hot-melt system. The material is melted, compressed, and extruded into high-density blocks or logs, which are then cooled and solidified. These compact outputs can also be further processed into recycled EPS pellets, making them suitable for reuse in manufacturing.
GREENMAX MAR Series Styrofoam densifier provides a reliable, low-labor, and environmentally friendly solution for converting bulky Styrofoam waste into compact, high-value recyclable material.
GREENMAX Styrofoam Densifier Works
1. Crushing – Foam waste is crushed into smaller pieces.
2. Heating & Melting – The densifier melts the foam, removing air and reducing volume.
3. Compression & Extrusion – Molten foam is squeezed into dense blocks or logs.
4. Optional Pelletizing – The material can be further processed into EPS pellets for reuse.
This process can reduce foam volume by up to 90%, significantly lowering disposal costs while generating valuable recyclable material.
GREENMAX Styrofoam Densifier Capacity
GREENMAX Styrofam densifier M-C100: 100 kg/hGREENMAX Styrofoam densifier M-C200: 200 kg/h
GREENMAX Styrofoam densifier M-C300: 300 kg/h
After shredding, heating, and extrusion, Styrofoam is transformed into high-density ingots with a volume reduction ratio of up to 90:1. This densified material, often referred to as PS ingots, is compact and easy to handle, significantly reducing storage requirements and transportation costs.
GREENMAX Styrofoam Densifier Functions
1. Crushing the waste Styrofoam(polystyrene foam) and melt into tight ingots with a 90:1 compression ratio, which saves warehouse space.
2. After hot-melting, Styrofoam(polystyrene foam) can sell for reusing and making frame products.
3. Keep more waste Styrofoam(polystyrene foam) from being landfills or burned.
4. Protect the environment, save raw material to reduce the energy crisis pressure and improve the pollution.
GREENMAX Styrofoam Densifier Advantages
1. GREENMAX are manufacturing many models with different outputs.
2. The machine can be designed as a requirement.
3. GREENMAX provide after-service in time, there are local engineers ready for support.
Why Choose GREENMAX for Styrofoam Recycling
1. Suitable for all kinds of foam materials, such as XPS, PSP, EPE, and EPP
2. Occupy less space as Mars can melt the Styrofoam into dense blocks
3. As the biggest end use of recycled Styrofoam(EPS), we guarantee to buy Styrofoam back at a very good price.
Styrofoam Recycling in Different Industries
Appliance Store Case
As a local professional appliance retailer, Grand Appliance & TV was growing very fast now. After moving to the new huge warehouse, Anish is thinking about improving their recycling rate, because their old densifier was too slow and not work properly.
Recently we met Anish and talk about his upgrade plan, he installed a GREENMAX styrofoam densifier in the new warehouse, no problem to recycle all his scrap. Over the past several years, due to the nice work of Styrofoam densifier, not only saving a lot of scrap landfill cost, to his surprise, saving a lot of labor cost. Only looking at the recycling profit, there is one load each month, the amount is almost $10,000.
Furniture Store Case
As the #1 furniture retailer in the world, ASHLEY Furniture is leading every job they are doing, including styrofoam recycling part. With the advanced concept, ASHLEY has been doing recycling for around 20 years in all their warehouses.
Michael Kotlarz came to us recently and wants to find a better solution provider, the current solution is not providing service anymore. Since that time, they are using GREENMAX styrofoam densifier in their DC. Michael has been working in ASHLEY for more than 30 years, and he started the recycling project from the beginning. Till now, GREENMAX has been working with ASHLEY for 3 locations, including California DC, Florida DC, and Chicago DC. Michael did do an analysis of effects, comparing the material profit, SAVING is the most valuable number, the total Saving cost statistics for the group is over $10,000 every year, and improving the warehouse efficiency at least 30%.
Foam Manufacturer Case
As a local professional packaging manufacturing company, Maven Packaging is manufacturing all kinds of packaging to improve customer’s life, EPS foam is a necessary packaging. In their Alabama plant, they spent $2,000 per month to dispose of their waste coolers. Recently, Bryan Clark came to us and said this waste problem takes her lots of time, it’s necessary to change another way other than landfill.
Maven Packaging installed GREENMAX Styrofoam densifier to recycle their waste Styrofoam scrap, and they are making one truckload every 2 months, get $5,000 value each month. Other locations also plan to study this recycling solution and improve its recycling rate.
Packaging manufacturer Case
Insulation Tech is a professional Styrofoam(EPS foam) manufacturing company from Massachusetts, They generate at least 4 trailers of foam leftovers each month, they used to send foam scrap landfill or some company can accept this scrap in the past. As their business growing, Nancy Barone(owner) realized it’s time to change the situation, otherwise, it took a lot of space before disposal, and should cost more and more landfill in the future. At present, Nancy got our information through another friend and looking for a more effective solution.
GREENMAX styrofoam hot melting densifier was installed in the warehouse recently, Nancy is no need to spend time thinking about the landfill cost and how to disposal. During past 1 year, they saved at least $15,000 landfill cost, and over $10,000 profit through selling the melted Styrofoam.
GREENMAX Styrofoam Recycling Machine Mars Models
GREENMAX Foam Densifier M-C100Throughput: 100kg/h
EPS Compression Ratio: 90:1
Compressed EPS Density: 600-800kg/m3
Motor Power: 22.9kw
Throughput: 200kg/h
EPS Compression Ratio: 90:1
Compressed EPS Density: 600-800kg/m3
Motor Power: 37.5kw
GREENMAX Foam Densifier M-C300
Throughput: 300kg/hEPS Compression Ratio: 90:1
Compressed EPS Density: 600-800kg/m3
Motor Power: 37.5kw