How to Choose a Foam Densifier
Two processes, one decision. This guide compares hot melt and cold compaction densifiers, then helps you size a machine by the foam volume you actually generate.
Hot Melt vs Cold Compaction
| Aspect | Hot Melt | Cold Compaction |
|---|---|---|
| Process | Melts the foam with heat and extrudes it as solid ingots. | Compresses the foam mechanically, with no applied heat, into dense blocks. |
| Volume reduction | 90:1 | 60:1 |
| Output form | Solid ingots | Dense blocks |
| Foam handled | EPS / EPE / EPP | EPS / PUR / PIR |
| Best suited to | Sites with a steady, high volume of EPS packaging waste, where the highest possible reduction ratio and a compact, tradable ingot matter most. | Mixed foam streams including PU and PIR, and sites where a heated process is unwanted or the material must stay unmelted. |
| Models available | FD-10FD-12FD-15FD-25FD-50FD-100FD-335 | FD-1010FD-2000FD-3000 |
Sizing by Throughput
Size the machine by the foam you generate per shift, not by an occasional peak. Every model below is currently available; capacities are the maximum rate for EPS.
| Model | Process | Capacity (EPS) | Reduction |
|---|---|---|---|
| FD-100 | Hot Melt Foam Densifier | 2000 lbs/hr (907 kg/h) | 90:1 |
| FD-50 | Hot Melt Foam Densifier | 1000 lbs/hr (454 kg/h) | 90:1 |
| FD-335 | Hot Melt Foam Densifier | 1000 lbs/hr (454 kg/h) | 90:1 |
| FB-8000 | Foam Shredder | 800 lbs/hr (363 kg/h) | 30:1 |
| FD-3000 | Cold Compaction Foam Densifier | 500 lbs/hr (227 kg/h) | 60:1 |
| FD-25 | Hot Melt Foam Densifier | 300 lbs/hr (136 kg/h) | 90:1 |
| FD-15 | Hot Melt Foam Densifier | 250 lbs/hr (113 kg/h) | 90:1 |
| FD-2000 | Cold Compaction Foam Densifier | 200 lbs/hr (91 kg/h) | 60:1 |
| FD-12 | Hot Melt Foam Densifier | 150 lbs/hr (68 kg/h) | 90:1 |
| FD-10 | Hot Melt Foam Densifier | 50 lbs/hr (23 kg/h) | 90:1 |
| FD-1010 | Cold Compaction Foam Densifier | 45 lbs/hr (20 kg/h) | 60:1 |
Frequently Asked Questions
- Hot melt or cold compaction — which one should I choose?
- Hot melt melts the foam and extrudes solid ingots, reaching the highest volume reduction; it suits a steady, high volume of EPS. Cold compaction applies no heat and produces dense blocks; it suits mixed foam streams including PU and PIR, and sites where a heated process is not acceptable. Tell us your foam type and daily volume and our engineers will recommend a model.
- What happens to the foam after it is densified?
- Densified EPS is a tradable commodity. Recyclers buy ingots and blocks as feedstock for products such as picture frames and construction mouldings. Densifying also cuts landfill and hauling costs, because the same amount of scrap ships in a fraction of the trucks.
- How do I work out the capacity I need?
- Start from the foam you actually generate per shift and add headroom for growth, rather than sizing for a rare peak. Compare that figure against the capacity column below; if your volume falls between two models, the larger one leaves room and runs at a lower duty cycle.
- Do I also need a shredder?
- A shredder is a pre-processing step, not a replacement for a densifier. It breaks bulky or awkward pieces down so they feed evenly, which matters when the scrap arrives as large mouldings or when you want to buffer material before densifying.
Not sure which model fits?
Send us your foam type, the volume you generate and any space or power constraints. Our engineers will come back with a specific model and options.
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