What types of foam are recyclable?

According to the EPA, over 3 million tons of foam products and packaging are produced annually in the USA. Of that, only about 5,000 tons are recycled. Foam takes up valuable landfill space, degrades slowly, and fragments to pollute the soil and water.

Foam should be recycled to prevent environmental degradation and preserve valuable raw materials. These types of foam can be recycled:

• Polystyrene
• Polyethylene foam
• Polyurethane foam

We’ll discuss recyclable foam in greater detail, learn about the benefits of foam recycling, and recommend the baling wire products you’ll need to do the job right.

Polystyrene

Polystyrene foam is made by expanding polystyrene beads using steam and blowing agents, creating a structure that is about 95–98% air. It is commonly made into:

• Packaging materials: Protective packaging for electronics and other fragile items, packing peanuts, food packaging, and containers.
• Insulation: Building insulation (walls, roofs, foundations) and insulation for refrigerators and freezers.
• Food items: Disposable cups, plates, food containers, egg cartons, and meat trays.
• Construction materials: Insulating concrete forms and architectural moldings.
• Recreational products: Surfboards, coolers, and ice chests.
• Automotive parts: Energy-absorbing components in car doors and child safety seats.

Although polystyrene is 100% recyclable, less than 10% of it undergoes recycling. Polystyrene’s low density makes recycling economically unviable. When it ends up in the environment, it takes hundreds of years to biodegrade and pollutes the soil and air.

Polyethylene foam

Polyethylene is also a 95–98% air material made of expanded beads. It is used to make similar products to polystyrene, but it is considered a #4 plastic for recycling. It is also 100% recyclable, but too light and voluminous for efficient transportation and processing.

Polyurethane foam

Polyurethane is formed through the chemical reaction of polyols and isocyanates. It can be soft or rigid, open-cell (and breathable) or closed-cell (and retentive). It is used to make products such as:

• Furniture and bedding
• Automotive seating and interior components
• Insulation for buildings and appliances
• Footwear (shoe soles)
• Carpet underlay
• Medical devices and equipment
• Sports equipment (padding, helmets)
• Soundproofing materials
• Filters for air and water systems

Polyurethane foam is much more dense and durable than polystyrene or polyethylene. It can be shredded and used as is, or it can undergo chemical recycling and be reformed into new products. However, widespread polyurethane recycling programs don’t exist yet due to economic infeasibility.

The foam recycling process

Here is the general process by which used foam materials are recycled and reused:

1. Collection: Foam waste is gathered from homes, businesses, and industrial sources. It is then sorted and separated from other materials. Sorted foam is transported to recycling facilities.
2. Cleaning:Contaminants and non-foam materials are removed.
3. Size reduction: Large foam pieces are shredded or ground into smaller particles.
4. Compression: Shredded foam is compressed using specialized equipment (e.g., densifiers or compactors) to prepare it for transportation to processing facilities.
5. Melting:Compressed foam is heated and melted in an extruder.
6. Degassing: Air and other gasses are removed from the melted foam.
7. Filtering: Melted foam is filtered to remove remaining impurities.
8. Pelletizing: The molten foam is extruded through small holes and cut into uniform pellets.
9. Cooling and packaging: Pellets are cooled and packaged for transport.
10. Transportation to manufacturers: Recycled foam pellets are shipped to manufacturers.
11. Reprocessing: Manufacturers melt the recycled pellets and combine them with virgin materials if needed.
12. New product creation: The recycled foam material is used to create new products.

As technological advancements drive down the costs associated with foam recycling, foam has the potential to become a highly sustainable product.

What types of foam can’t be recycled?

These foam products are not recyclable due to contamination or infeasibility:

• Products contaminated by food
• Insulation materials with flame-retardant additives
• Foam products mixed with other materials
• Biodegradable foam that isn’t meant to be reused

The low recycling rate for foam is based on economic feasibility limitations and not processing limitations.

Market forecast for foam recycling

The global foam recycling industry is poised for moderate growth in the coming years, driven by increasing environmental concerns, developments in transportation and processing, and the rising volume of foam waste.

The global foam market should see a compound annual growth rate of 4.7% between 2024 and 2034. As foam production expands, recycling efforts will follow. Key growth areas include expanded polystyrene and polyurethane foam recycling, particularly in the packaging and construction industries. Biodegradable foam is also likely to grow in popularity.

Learn about foam bale prices.

The benefits of recycling foam

There are several benefits to recycling foam, including:

• Environmental protection: Foam recycling prevents toxic chemicals from spreading into the environment.
• Greenhouse gas reduction: Foam recycling reduces carbon emissions associated with virgin resource acquisition and manufacturing.
• Conservation of natural resources: Recycling foam reduces the need for new raw materials.
• Job creation: The recycling industry generates employment opportunities through foam collection, processing, and recycling.

By prioritizing foam recycling, individuals and organizations contribute to a healthier and more sustainable future and the circular economy model.

Best baling wire for foam recycling

Baling Wire Direct offers multiple wire options for baling foam and other recyclables. The best type of wire for baling foam will also depend on storage conditions and duration. Foam bales are light, so high gauge wire is sufficient. For vertical balers, we recommend 12–14 gauge wire. For horizontal balers, we recommend 11–14 gauge wire, and for two-ram automatic balers, we recommend 11–13 gauge wire.

Here are some of the best options:

• Galvanized wire has undergone hot-dip galvanization to provide extra resistance against rust and other forms of corrosion, perfect for foam bales that require outdoor storage.
• Black annealed wire has a wax finish that helps it feed smoothly through high-volume automatic baling machines commonly used in foam recycling. Annealing improved the wire’s elongation traits, which allows black annealed wire to handle expansive foam bales.
• Single loop bale ties can be tied to different lengths to accommodate irregular shapes and inconsistent bale sizes. They work with manual horizontal and vertical balers. We offer both black annealed and galvanized single loop bale ties. Galvanized bale ties offer enhanced abrasion resistance for baled recyclables that are often handled roughly.
• Double loop bale ties are pre-cut to length. The double loop configuration accelerates the tying process, increasing productivity.

Talk to us if you’d like help choosing the best wire for your operation.