In 1988, The Society of the Plastics Industry (SPI) gave symbols and numbers to different types of recycled materials. These numbers are placed inside a three arrow triangle recycling symbol, at the bottom of most plastic containers. The number tells us what type of plastic the material is made of. Since some materials needs to be recycled in a different way than others and cannot be mixed, this recycling number system helps us in classifying, separating and sorting out the different types of plastics. The recycling codes consist of numbers from 1 to 7. Number 6 consists of plastic and foam cups, disposable food trays and food containers, foam packaging material for electronics and furniture, egg cartons, foam peanuts and medical coolers. Number 6 is Polystyrene foam, also commonly referred to as Polystyrene, Expanded Polystyrene or EPS foam, which is the one I will concentrate on in this article.

Polystyrene is one of the most common forms of plastic. The material is a mixture of about 98% air and only 2% polystyrene; it is water and heat resistant, therefore it is an excellent insulator. Due to its popularity, the global demand for EPS and its production is increasing and therefore the need for recycling methods. Since EPS consists mostly of air, by recycling it and putting it through a recycling process we can significantly reduce its volume.

The first stage in recycling Styrofoam would be the cleaning and sorting process. The material is inspected and all other contaminants are removed. In the next stage, the foam is fed into recycling machines that use either cold compaction or thermal densification. The foam compactor uses the cold compaction and basically compresses the foam into dense logs, thus reducing its volume by 98% volume reduction. A foam densifier machine on the other hand uses thermal compaction. The densifier uses heat and friction to melt the foam, then pressing and pushing the melted material. The end result is long narrow strands. In the last phase, after the compacted material has cooled down, it is cut into pellets which make it easier to be transported. The recycled foam is then shipped to other manufacturers for creating new plastic products.

There is a great benefit for recycling foam, especially Styrofoam number 6, and we can create new cost-effective materials and products from it. The recycled material can be used to create picture frames, pens and office supply, clothes hangers, curtain rods, outdoor furniture, CD cases, toys and pony packs for growing and transporting seeds and plants. It can also be used to create architectural mouldings, ornamental home décor and Structural Insulated Panels and it is a great source of insulation material. Recycled EPS can be mixed with wood or concrete to serve as excellent building insulation agent, since it is water, mold and decay resistant.

Using recyclable foam rather than the raw original material to create new products has many benefits. It saves natural resources, it reduces littering and pollution, it saves landfill space and uses less energy. Recycled foam has real value for manufacturers of new products willing to pay well for the recycled material. Recycling foam has become much easier and more efficient in recent years with the advances in technology; recycling equipment now reduce the volume of the foam by up to 95% its original size and requires much less labor than it used to in the past. Recycling basically results in reduction of landfills and creates a more sustainable green environment for us all.