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/h
GREENMAX 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 to 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 retailers, furniture distribution centers and foam manufacturers generate Styrofoam waste from different sources. Their handling needs also vary, from keeping warehouse space available to managing a steady flow of production scrap. These four cases show how businesses use GREENMAX Styrofoam densifiers to reduce disposal costs and recover material value.

Appliance Retailer: Grand Appliance & TV

Grand Appliance & TV needed to improve its foam recycling process after moving to a larger warehouse. Its existing densifier was too slow and unreliable to keep up with the volume of discarded packaging.

The retailer upgraded to a GREENMAX Styrofoam densifier to process its warehouse foam waste. Over several years of operation, the equipment helped reduce landfill expenses and the labor required to handle bulky scrap. The company reported shipping approximately one load of densified material each month, with a material value of nearly $10,000 per load.

Furniture Distribution Centers: Ashley Furniture

Ashley Furniture had been recycling Styrofoam in its warehouses for around 20 years when it approached GREENMAX for a replacement solution. Its previous provider was no longer offering service, so maintaining support for its recycling operations became a priority.

GREENMAX supplied Styrofoam densifiers for three Ashley distribution centers in California, Florida and Chicago. Michael Kotlarz, who helped establish the company’s recycling program, evaluated the results and found that operational savings were more valuable than material sales alone. According to the case figures, the group saved more than $10,000 annually and improved warehouse efficiency by at least 30%.

Packaging Manufacturer: Maven Packaging

At its Alabama plant, Maven Packaging was spending approximately $2,000 per month to dispose of waste EPS coolers. Managing this bulky waste also took up staff time, prompting the company to look for a recycling alternative.

A GREENMAX Styrofoam densifier enabled the plant to turn loose foam scrap into dense material for collection and sale. The company reported producing one truckload every two months, with an average recovered material value of approximately $5,000 per month. The results also encouraged other locations to evaluate the same approach.

EPS Manufacturer: Insulation Tech

Massachusetts-based Insulation Tech generated at least four trailer loads of EPS production scrap each month. The company previously relied on landfill disposal or outside businesses willing to accept the loose foam. As production grew, scrap occupied more storage space while awaiting removal, and disposal costs became a greater concern.

After adopting a GREENMAX Styrofoam hot-melt densifier, Insulation Tech could reduce the volume of its scrap and sell the densified material. During the first year covered by the case, the company reported saving at least $15,000 in landfill costs and generating more than $10,000 from material sales.

GREENMAX Styrofoam Recycling Machine Mars Models

GREENMAX Foam Densifier M-C100
Throughput: 100kg/h
EPS Compression Ratio: 90:1
Compressed EPS Density: 600-800kg/m3
Motor Power: 22.9kw

GREENMAX Foam Densifier M-C200
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/h
EPS Compression Ratio: 90:1
Compressed EPS Density: 600-800kg/m3
Motor Power: 37.5kw