Struggling with Foam Scrap? How AD Series Densifiers Solve Volume and Handling Issues

Foam scrap creates one of the most persistent waste challenges in manufacturing environments. While it weighs very little, it consumes a huge amount of floor space, disrupts material flow, and increases disposal and transportation costs. Facilities that process EPS, EPE, EPP, or PE foam often find that traditional collection methods fail to keep pace with production volumes.

At JTW International, we design systems that address foam scrap as an operational problem, not just a waste issue. The AD Series Densifiers are engineered to reduce volume, stabilize handling, and convert loose foam into a manageable, recyclable material stream.

Why Foam Scrap Becomes a Facility Bottleneck

Foam scrap accumulates quickly near cutting, molding, and trimming stations. Because of its low bulk density, even small production runs can overwhelm bins and collection areas. This leads to frequent haul-offs, cluttered workspaces, and inefficient use of valuable floor space.

Loose foam is also difficult to transport. Trucks fill up long before reaching weight limits, resulting in high freight costs per pound. In many facilities, foam scrap remains a recurring expense with no recovery path.

The Role of Foam Shredding & Conveying in Scrap Control

Foam scrap becomes problematic when it enters the waste stream without size control or flow regulation. Large, irregular pieces trap air, feed inconsistently, and overwhelm collection areas. Foam Shredding & Conveying resolves these issues by stabilizing scrap before densification.

Why shredding is essential

• Reduces foam into uniform, processable pieces

• Prevents bridging and inconsistent compression

• Enables continuous, predictable material flow

• Reduces manual handling and floor-level accumulation

Shredding is not about volume reduction alone. It conditions the material so that densification can occur efficiently and repeatably.

How conveying improves system performance

• Transfers scrap directly from production points to processing equipment

• Maintains consistent feed rates aligned with densifier capacity

• Eliminates surge loading that disrupts density control

• Keeps scrap movement off the floor and out of work zones

When shredding and conveying are engineered together, scrap handling becomes a controlled process rather than a reactive cleanup task.

How the AD Series Densifier Works

The AD Series Densifier operates as a continuous, staged system designed to remove air, stabilize density, and produce a uniform output suitable for transport and recycling.

Step 1: Industrial shredding for feed consistency

Foam scrap enters a heavy-duty industrial shredder engineered for continuous operation.

• Full-Melt Auger Densifier processes EPS, EPE, and EPP reliably

• Direct-coupled gearmotors deliver consistent torque

• Heavy-duty bearings support long-duty cycles

This stage ensures material enters the densifier at a controlled size and rate, which is critical for maintaining density and throughput.

Step 2: Controlled transfer into the densifier

Shredded material moves directly into the densification chamber without intermediate handling.

• Eliminates material buildup between stages

• Maintains steady throughput

• Prevents air pockets caused by uneven feeding

This controlled handoff allows the system to operate continuously rather than in batch cycles.

Step 3: Foam Scrap Auger Densifier compression

Inside the chamber, the Foam Scrap Auger performs the core densification process.

• Heat releases trapped air and gases

• The auger applies uniform, controlled compression

• Material transitions from loose scrap into a dense mass

This auger compression  process removes air without degrading the material, preserving recyclability while achieving high density.

Step 4: Brick formation and stabilization

Compressed material exits the chamber and is collected in a brick mold/form. Once the brick form is full, the form is removed, and you have a densified brick of material.

• Bricks retain shape after cooling

• No baling wire or strapping required

• Output is stackable and easy to palletize 

The result is a stable, predictable product designed for efficient storage, transport, and resale.

Volume Reduction That Changes the Economics

The AD Series achieves densification ratios of up to 90:1, depending on material type and target density. This level of compression allows facilities to load up to 40,000 pounds of densified foam into a standard 40-foot container.

From an operational standpoint, this means fewer truckloads, reduced freight costs, and more predictable logistics planning. Foam scrap stops being a constant drain on resources and becomes a controllable material flow.

Handling and Storage Advantages

Densified foam bricks solve one of the most overlooked issues in scrap management: handling. Loose foam requires constant attention, frequent cleanup, and excessive storage space. In contrast, AD Series output is stable, stackable, and easy to palletize.

Facilities using the AD Series report cleaner work areas, reduced housekeeping labor, and safer material movement. Vertical storage becomes practical, freeing floor space for production rather than waste.

Flexibility Across Foam Types

The AD Series is designed to process EPS, PE foam, EPE, and EPP, whether clean or dirty. This flexibility reduces the need for sorting and multiple disposal workflows. One system can manage diverse foam scrap streams without constant adjustment.

This capability is especially valuable in facilities running multiple product lines or variable foam materials throughout the day.

Engineered Shredding Systems Built for Throughput

Not all shredders are created equal. JTW’s Engineered Shredding Systems are purpose-built for foam densification, not general waste reduction. Each shredder is sized to match densifier capacity, ensuring consistent feed rates and avoiding bottlenecks.

By pairing a properly sized industrial shredder machine with the Foam Scrap Auger Densifier, the AD Series maintains steady throughput and predictable output density.

Configurations for Real-World Operations

The AD Series is available in multiple configurations, including single-outlet, heavy-duty, and dual-outlet models. Throughput ranges up to 400 pounds per hour, depending on material and density targets. Optional integrations include infeed conveyors, fume exhaust systems, remote shredders, and expanded material handling layouts.

These options allow the system to fit into existing production environments without forcing workflow changes.

Turning Scrap Into a Recoverable Asset

Once densified, foam bricks can be sold to recyclers, shifting scrap from a disposal cost to a recoverable material. Even partial recovery offsets operating expenses and improves overall waste economics.

This is not about sustainability messaging. It is about making foam scrap predictable, manageable, and financially rational.

Take Control of Your Foam Scrap Today

If foam scrap is consuming space, driving disposal costs, or disrupting your operation, the AD Series Densifiers offer a proven path forward. At JTW International, we design systems that work on real factory floors, not just on paper.

Contact JTW International today to discuss your foam scrap volume, material types, and facility layout. Let our team engineer a densification system that reduces waste costs, improves handling, and delivers measurable operational control.