That white foam packaging protecting your new TV or keeping your takeout hot? Most people call it styrofoam, but it’s technically expanded polystyrene (EPS). And while it seems like it should just go in the trash, there’s actually a way to recycle it—turning bulky foam into picture frames, crown molding, and even insulation.
But here’s the thing: recycling styrofoam isn’t as simple as tossing it in your blue bin. We’ll walk you through what happens to recycled styrofoam, where it goes, and how you can actually get rid of it responsibly.
What Actually Is Styrofoam ?
Let’s clear this up first. True Styrofoam™ is a trademarked product made by DuPont, used mainly in construction and insulation. What you’re probably dealing with—those foam cups, egg cartons, and packaging blocks—is expanded polystyrene, or EPS.
EPS is made from petroleum, but it’s uniquely comprised of more than 90% air.[4] That’s why it’s so lightweight and takes up massive amounts of space. Products made of these foam materials are 90% air and they can take up approximately 30% of landfill space by volume.[4]
And the environmental impact? Not great. Scientists speculate it will take at least 500 years for polystyrene to break down, if it ever does at all.[3] That packaging from your online order could outlast several generations.
How Recycled Styrofoam Gets Processed
The recycling process for EPS isn’t what you’d expect. Because foam is mostly air, recyclers need to remove that air before they can do anything useful with it.
First, the foam gets collected and sorted. To recycle foam packaging, it is cleaned then shredded before being melted down into a paste then turned into pellets.[3] There are two main methods for densifying foam: mechanical compaction and thermal densification.
With mechanical compaction, compactors take the shredded material and compress the foam into tight blocks, reducing the volume of the foam by up to 1/50th of its original volume.[4] The blocks look neat and dense—nothing like the bulky material that came in.
Thermal densification works differently. Foam densifiers transfer the material to a plastic extruder where the foam is exposed to heat and pressure to be melted into a paste.[4] This method is more efficient and results in even denser blocks ready for transport.
Some companies are trying newer approaches. Another method is using a liquid hydrocarbon known as Limonene, which can be extracted from citrus fruits, to dissolve the foam. Sony Corporation of Japan has been using this process as an environment-friendly method of foam recycling.[4]
Products Made From Recycled Styrofoam
Once the foam is densified into those compact blocks or pellets, it heads to manufacturers who turn it into new products. These pellets are used to manufacture new products such as picture frames, interior molding, and office supplies.[3]
But the list goes much longer. Recycled EPS can be used to make items like outdoor furniture, roofing tiles, coat hangers, seedling containers, door and window frames, packing peanuts and so much more.[1]
Construction materials are big users of recycled foam. EPS has become extremely popular in the construction industry. It’s used to make insulated concrete forms and other structural panels, thus helping to make building practices more sustainable.[1] When mixed with concrete, it creates lightweight prefabricated blocks that are easier to work with.
There’s one catch though. Recycled EPS can’t be used to make insulated cups, foam trays or anything else that will come in contact with food.[1] Health regulations require virgin materials for food-contact items, which limits some recycling applications.
Where to Recycle Styrofoam Near You
Here’s where recycling foam gets tricky. Most recycling facilities don’t have the equipment needed to densify EPS, so to recycle it, it has to be taken to a special location where it can be densified.[6]
Many areas have drop-off locations specifically for foam recycling. Some larger recyclers like Dart Container operate their own collection networks. All locations accept used polystyrene foam including post-consumer foam cups and “to-go” containers, egg cartons, ice chests, rinsed meat trays, protective packaging foam, and other foam with the #6 inside the chasing arrows triangle.[1]
You can find local options through databases like Earth911.com or the EPS Industry Alliance recycling map. Some municipalities run their own programs—check with your local waste management department. A few areas even offer mail-in programs if you don’t have nearby drop-off access.
Before you drop off foam, make sure it’s clean and dry. Most locations won’t accept dirty foam or food-contaminated containers. Remove tape, labels, and any non-foam materials.
At CBRH Global, we understand the importance of proper material handling and recycling. While we specialize in various plastic materials like PE, PET, and PP, we recognize that sustainable practices across all plastic types matter. Learning about polystyrene insulation can also help you understand the broader applications of these materials.
Why Recycling EPS Is Worth the Extra Effort
Look, we get it—driving to a special drop-off location isn’t as convenient as tossing foam in your regular recycling bin. But there are real reasons why it matters.
For every kilo of EPS that is recycled, the use of 2 litres of oil is saved.[2] That’s a direct reduction in petroleum consumption. And because foam takes up so much landfill space, recycling it means we’re not filling valuable land with material that won’t decompose for centuries.
It tends to be cheaper to produce new polystyrene products from used ones. This method is highly effective when it comes to packaging materials.[1] So unlike some materials where recycling is more expensive than making new products, recycled EPS actually makes economic sense.
The recycling rates are improving too. In 2016, more than 118 million pounds of expanded polystyrene was recycled in the United States alone. When initially tracked in 2010, that number was around 69 million.[1] More people are figuring this out and taking action.
The Challenges That Still Exist
We won’t sugarcoat it—styrofoam recycling has obstacles. EPS is comprised of more than 90% air, which makes it lightweight and bulky. These properties mean the collection and transportation impacts of recycling EPS often outweigh the environmental benefits.[6]
Transportation costs are real. Hauling truckloads of material that’s mostly air doesn’t make financial sense unless that foam gets compacted first. That’s why specialized equipment is needed and why most curbside programs can’t handle it.
Americans dump approximately 1,500 tons of polystyrene in landfills daily, and less than 1% of it is recycled.[7] That recycling rate is shockingly low, but it reflects the infrastructure gap—not the recyclability of the material itself.
Some states have started banning EPS products altogether. As of recent years, Oregon, California, Delaware, Rhode Island, Hawaii, and Washington have passed legislation restricting various foam products. These bans reflect frustration with the current recycling system and growing concern about environmental persistence.
Conclusion
Recycled styrofoam has a second life as picture frames, building materials, outdoor furniture, and dozens of other products. The recycling process works by compressing or melting foam to remove the air, turning bulky waste into dense blocks that manufacturers can use.
The infrastructure for EPS recycling is growing, but it requires extra effort. You’ll need to find a specialized drop-off location rather than using your curbside bin. That extra step makes a real difference—saving petroleum, reducing landfill waste, and supporting a market for recycled materials.
Make sense? Next time you’re unpacking something wrapped in foam, don’t just toss it. Look up your local drop-off location and give that material another purpose.
FAQs
Can you put styrofoam in regular recycling bins? No, don’t put styrofoam in your curbside recycling bin. Most facilities can’t process it, and it’ll contaminate other recyclables. Instead, look for specialized drop-off locations that have equipment to compress and recycle foam. Check Earth911.com or your local waste management website for nearby options.
What products are made from recycled styrofoam? Recycled styrofoam becomes picture frames, crown molding, outdoor furniture, coat hangers, seedling containers, door frames, insulation panels, and construction materials. It can even be mixed with concrete for lightweight building blocks. The main restriction is that recycled foam can’t be used for food-contact items like cups or plates.
Why is styrofoam so hard to recycle? Styrofoam is 90% air, which makes it bulky and expensive to transport. Recyclers need specialized equipment called densifiers to compress or melt the foam before processing. Most curbside programs don’t have this equipment, so foam must go to dedicated facilities. The low value and high transportation costs make it economically challenging.
How long does styrofoam take to decompose? Styrofoam takes at least 500 years to break down in a landfill, and it may never fully decompose. It can break down faster with continuous sun exposure, but when buried under other waste in landfills, it essentially lasts forever. This long lifespan is why recycling or reducing styrofoam use matters so much.
Is all white foam the same as styrofoam? Not exactly. True Styrofoam™ is a trademarked product used in construction. Most packaging foam is expanded polystyrene (EPS), marked with a #6 recycling code. Some foam products that bend instead of snap aren’t EPS and can’t be recycled the same way. Check for the #6 symbol and test if it breaks cleanly when bent.