In October 2016, Sussex County Municipal Utilities Authority (SCMUA) installed a self‑contained Foam Cycle densifier at its landfill drop-off center—becoming one of the earliest New Jersey counties to treat EPS as a resource instead of waste (waste360.com). Since then, the system has processed over 4,000 lb of clean packaging foam, significantly reducing landfill volume.
The Foam Cycle unit compresses EPS at the point of collection—achieving a 95% volume reduction—and converts loose foam into dense ingots. SCMUA’s success hinged on two system pillars: evoking public awareness with clear signage and training staff on maintenance and operation.
System logistics: Compact and connect
- Onsite collection: Residents deliver clean EPS to existing landfill drop-off hubs, where labeled bins guide proper sorting.
- Densification: The Foam Cycle unit grinds, melts, and presses foam into ingots stored onsite (waste360.com, warrencountynj.gov).
- Market link: SCMUA collaborated with Foam Cycle to establish a local buyer—typically a picture-frame manufacturer—to complete the circular loop .
This setup integrates directly with existing infrastructure, avoiding curbside complexity while delivering practical EPS recovery.
Why this matters
Sussex County’s project shows that county authorities can reclaim landfill space and generate material value through modest capital investment. The model achieves:
- Operational simplicity—integrating densification into routine drop-off center operations
- Community engagement—making EPS recycling accessible and visible
- Feedstock supply—creating a direct path from foam to recycled consumer goods
SCMUA’s experience reframes EPS from bulky landfill waste into a manageable and reusable material—providing a template for counties, hospitals, and campuses aiming to mainstream foam recovery.
FACT BOX
| Item | Value |
| Launch | October 2016 |
| Location | Sussex County, New Jersey, USA |
| Equipment | Foam Cycle densifier (95% volume reduction) |
| Material processed | 4,000 lb (to date) |
| Collection point | Landfill drop-off center |
| End-use material | EPS ingots sold to local picture-frame manufacturer |
| Infrastructure saved | Landfill space & virgin material usage reduction |
Source:
“How a New Jersey County is Tackling Foam Recycling” — Waste360, 7 June 2017 (waste360.com, foamcycle.com, montclair.edu, monroetwp.com)
