How much do bales of foam weigh?

The weight of a foam bale can go up to 5000 lb, with the average weight for mill-size bales being around 750 lb. Average bales measure approximately 30 x 48 x 60 inches.

Learn about foam bales and what affects their weight. Partner with Baling Wire Direct for US-made baling wire for foam recycling.

How does bale size affect weight?

The weight of foam bales is based on size and density. Here is a comparison of common foam bale categories:

Bale size	Bale dimensions (inches)	Bale weight
Small	24 x 25 x 30	around 300 lb (136 kg)
Medium	30 x 48 x 60	around 750 lb (340 kg)
Large	Varies	around 5000 lb (2268 kg)

About vertical foam balers

Vertical balers produce lighter bales for recycling operations with low- and medium-volume needs. These machines use vertical hydraulic presses to compress foam materials into bales. Their chambers and presses are smaller than in horizontal balers and produce small- to medium-sized bales.

About horizontal foam balers

Horizontal baler machines handle higher volumes and generate larger bales of foam in industrial environments. The high press force of these heavy-duty balers compacts bales, which maximizes bale density and reduces transportation costs.

A horizontal, automatic foam baling press creates the heaviest, densest bales. Automated baling systems apply consistent pressure (e.g., 110,000 lb press force) to produce bales with minimal air gaps.

Does all foam weigh the same?

Not all foam weighs the same, even when baled. The weight of foam bales depends on the types of foam, the density of the foam scrap materials, and how it’s processed.

• Types of foam: Different types of foam can have different densities. Polyurethane foam, polyethylene foams, and re-bonded foam vary in weight based on their structure. For example, foam for furniture and foam for pillow fillings is usually softer and lighter, while rebonded foam, made from shredded high-density scrap, is heavier. This means a bale of soft cushion foam will weigh less than a bale made from dense rebond foam, even if they’re the same size.
• Form factor: How foam is prepared before baling affects its weight. Compressed foam that has been shredded or tightly packed into blocks will be denser and heavier than loose, uncompressed polyurethane foam scrap. The foam recycling process involves compressing large amounts of foam into bales to better manage the volume of foam waste.
• Contamination adds weight (but lowers value): If a bale contains non-foam materials like fabric, wood, or plastic from furniture manufacturing, it will weigh more, but the value of the clean foam scrap decreases. Recycling centers may pay less for contaminated bales because it’s harder to process them into new foam products.

What gauge baling wire is best for foam?

The baling wire gauge you should use for baling foam depends on two factors:

1. Number of wires your baler uses (typically 3 or 4).
2. Bale weight (heavier bales require stronger wire).

The combined load strength of all bale wires must exceed the weight of the foam bale to prevent breakage. Thinner wire is cheaper, so businesses should go with the thinnest baling wire that can safely bind their bales. For example, a 1,200-lb bale made by a 3-wire baler could use an 11 gauge wire since:

3 (# of wires) x 735 (load strength of 11 gauge black annealed stem wire) = 2,205 lb

Always follow your baler manufacturer’s wire recommendations, and contact us for wire selection assistance.

Here are our general wire gauge recommendations by bale weight:

Bale weight	3-wire baler	4-wire baler
Under 500 lb	12 gauge	13 gauge
500–1,000 lb	11 gauge	12 gauge
1,000–1,500 lb	10 gauge	11 gauge
1,500–2,200 lb	9 gauge	10 gauge

What type of baling wire is best for baling foam?

The most common types of baling wire used to bale foam are black annealed and hi-tensile galvanized wire. If you need to store bales for longer or in harsh conditions, use galvanized wire.

Black annealed wire

Black annealed baling wire is used for high-density bales that require flexibility, bales that are stored indoors, or bales stored for a short time. We offer black annealed by the box or stem. The benefits of black annealed wire for baling foam include:

• High tensile strength: secures dense bales of foam without snapping.
• Compatibility with automatic balers: feeds smoothly in high-volume machines (use box or stem black annealed wire).
• Elongation properties: stretches up to 25% to accommodate different densities of foam and shifting materials as bales settle.
• Some corrosion resistance: finished with a wax coat that provides minimal protection against moisture and corrosion.

High-tensile galvanized wire

High-tensile wire with a galvanized surface offers more load strength than regular wire and withstands extreme outward pressure from expandable materials, such as foam. 

We carry hi-tensile galvanized stem wire for two ram balers and high-throughput automatic foam baling presses. Choose between a simple Class 1 or more resilient Class 3 galvanization based on the level of resistance you need.

Bright wire

We also offer bright baling wire as single loop and double loop bale ties. Here’s why you should use bright bale ties to bale foam:

• Economical: uncoated steel wire is the cheapest option.
• Aesthetics: some operations prefer bright baling wire for client-facing applications.
• Indoor use: sufficient for dry environments.

Single loop bale ties can be tied to different lengths to accommodate for different bale sizes. They work with horizontal and vertical manual machines that bale foam. Double loop bale ties are pre-cut to length. The double loop configuration accelerates the tying process.