How Armstrong Brands Recycles Foam Locally — A Behind-the-Scenes Look

For more than 20 years, Armstrong Brands, Inc. has been committed to making EPS recycling simple, accessible, and environmentally responsible for our customers and our community. Long before sustainability became a buzzword, we believed that foam products should never be treated as single use items. Instead, they should be returned, densified, and transformed into something new.

Here’s a behind-the-scenes look at how our local recycling program works — and why it’s one of the strongest in the region.

Step 1: Collecting EPS From

the Community

Every week, Armstrong Brands receives foam from:

• Pharmacies

• Veterinarians

• Universities & research labs

• Hospitals

• Local food distributors

• Small businesses

• Community drop-offs

• Customers sending back used coolers

• Residents who want to recycle responsibly

We accept clean, white expanded polystyrene (EPS) of almost any shape coolers, protective packaging, molded parts, and more.

What We Accept

• EPS coolers (lid + base)

• Molded packaging pieces

• Loose EPS blocks

• Recycled-content EPS

• Biodegradable EPS from our newer eco-friendly lines

What We Don’t Accept

• Food-soiled foam

• Colored polystyrene

• Styrofoam plates/cups

• XPS (pink/blue construction foam)

• Packaging Peanuts

Step 2: Sorting, Cleaning & Preparing the Material

Once EPS arrives at our facility, our team:

1. Inspects it for contaminants

2. Removes tape, stickers, and labels (Please help us by removing before drop off)

3. Separates EPS from XPS or other plastics

4. Organizes material by size for efficient processing

Zero Waste During Manufacturing

Inside Armstrong Brands, we also operate with near-zero foam waste.
Most rejected or unusable EPS parts produced during manufacturing are ground up and reintroduced into our feedstock, where they become part of new molded foam products.
This internal recycling loop ensures that nothing goes to waste.

Step 3: Densifying the Foam

This is the heart of EPS recycling, and where the biggest environmental impact happens.

EPS begins as 98% air, which makes it bulky to transport. Our densifier compresses large amounts of foam into heavy, compact blocks.

✔ A 53’ Truckload Becomes 1.5 Pallet Spaces

To understand how effective densification is:
An entire 53-foot tractor trailer filled with loose EPS can be compacted down to roughly the size of one and a half pallet spaces.

This dramatic reduction:

• Lowers transportation costs

• Reduces carbon emissions

• Shrinks waste volume

• Makes EPS economical to recycle

Once densified, the blocks look like solid white bricks — dense, stackable, and ready for the next stage.

Step 4: Turning Recycled Foam Into New Products

The densified EPS blocks are shipped to manufacturers who transform them into:

• Picture frames

• Molding and trim

• Outdoor furniture components

• Home décor

• New packaging

• Polystyrene products

• And more

We also close the loop internally by producing 30–50% recycled-content EPS and offering biodegradable EPS bead options, giving customers sustainable solutions without sacrificing performance.

Step 5: Partnering With the Community

Our recycling program thrives because of the partnerships we’ve built over the last two decades. We work with:

• Local schools

• University environmental clubs

• Veterinary clinics

• Pharmacies

• Cold-chain suppliers

• Nonprofits and municipal groups

For organizations generating higher volumes, we offer pickup services to keep recycling simple and consistent.

Why Local Recycling Matters

When EPS is recycled locally at Armstrong Brands:

• Foam stays out of landfills

• Densified blocks minimize transport emissions

• Local manufacturers receive clean recycled material

• Waste-handling costs are reduced

• Businesses meet sustainability goals

And because our own manufacturing scrap is reused internally, the recycling loop becomes even more efficient.

A Better Way Forward

At Armstrong Brands, our EPS recycling program is about more than processing foam — it’s about responsible manufacturing, community partnership, and reducing waste at every step.

From reusing internal scrap to densifying entire truckloads of community foam into just 1.5 pallet spaces, we’re constantly improving the sustainability of EPS.

Whether you’re a business with weekly shipments, a school with seasonal projects, or a resident with old coolers, we’re here to help you recycle responsibly.

Join Our Recycling Network

📍 Drop-Off Location:
1703 Union Rd., West Seneca, NY 14224

📞 Phone: 716-677-2900
📧 Email: pshafer@armstrongbrands.com

♻️ Together, we’re reimagining EPS for you and the planet.