Koolfoam Adopts GREENMAX EPS Recycling System to Support Australia’s Zero-Waste Vision

With the global push toward sustainability, Polystyrene (PS/EPS) recycling has become a major focus in waste management. As a leading provider of recycling solutions, INTCO Recycling, through its brand GREENMAX, delivered a complete EPS recycling system to the long-established Australian foam manufacturer Koolfoam. This helped the customer demonstrate that polystyrene foam can be effectively reused and recycled, supporting the government’s environmental goals and ensuring the company’s sustainable future.

Customer Background: Koolfoam – A Leading Foam Manufacturer in Australia

Founded over 40 years ago, Koolfoam is a well-recognized foam producer in Australia. Its main products include:

Custom foam packaging

Pipe insulation materials

Thermal insulation for construction

However, the Australian government has announced plans to ban single-use EPS products, putting long-standing manufacturers like Koolfoam at risk of shutting down. To survive, Koolfoam needed a sustainable solution to prove that EPS waste can be recycled and reused.

Initial Need: From a Grinder to a Full EPS Recycling Solution

In 2021, Koolfoam first connected with INTCO Recycling through polystyrene waste purchasing. Shortly after, they reached out to GREENMAX for equipment that could recycle their production scraps. Initially, their request was for a grinder to crush waste polystyrene, allowing it to be reused in new foam blocks.

GREENMAX proposed a crushing + dust removal + dust collection system as the first step. However, after multiple conference calls and a deeper understanding of the customer’s long-term vision, it became clear that Koolfoam required a more comprehensive recycling solution.

The GREENMAX Solution: A Complete EPS Recycling System

GREENMAX provided Koolfoam with a customized full EPS recycling system that integrated seamlessly with their existing production line. The system included:

Grinding System – Efficiently crushing waste EPS materials

Dust Removal & Collection – Keeping the production line clean and improving recycled material quality

Sorting System – Separating high-quality beads for reuse

Blending System – Mixing virgin and recycled materials in different ratios

Through this solution, reusable polystyrene foam beads are recovered, while substandard beads are melted and compressed into foam ingots. These ingots are then purchased back by INTCO Recycling and transformed into new recycled products. This closed-loop approach ensures a 100% waste-to-resource transformation.

Results: Customer Satisfaction & Sustainable Growth

By 2022, Koolfoam had installed and started operating the complete GREENMAX recycling system. The customer expressed high satisfaction, recognizing the system’s efficiency and its alignment with government sustainability requirements. Thanks to GREENMAX, Koolfoam not only avoided the risk of being phased out but also established itself as a forward-thinking company in environmental responsibility.

Conclusion: Driving EPS Recycling and Circular Economy

This case highlights the critical role of the GREENMAX EPS Recycling System in supporting both policy compliance and business sustainability. With innovative recycling technologies, INTCO Recycling is helping companies like Koolfoam save costs, reduce waste, and contribute to Australia’s long-term vision of zero waste and a circular economy.