Closing the Loop – EPS Recycling and Circularity

Case Study Springvale EPS Ltd

About Us

Springvale EPS Ltd (Springvale) is the UK’s leading manufacturer of Expanded Polystyrene (EPS).

For over 50 years, we have supplied premium, high performance EPS products into the house building, construction, caravan, and other industries.

Our commitment to manufacturing excellence, technical expertise, and outstanding customer service has always been at the heart of our growth. Sustainability and responsibility are key pillars of how we operate, and our approach to EPS recycling and zero to landfill reflects our commitment.

We are proud members of the British Plastics Federation (BPF), actively engaging with the wider plastics industry and benefiting from the resources, guidance, and collaborative opportunities the BPF provides. This partnership supports our continuous improvement and reinforces our leadership in responsible EPS manufacturing.

Challenges

As a manufacturer of EPS insulation products, offcuts are an inevitable part of our processes. While EPS is 100% recyclable, we face challenges in handling:

  • Production offcuts efficiently.
  • EPS dust created during our manufacturing process.
  • EPS material returned by our customers.
  • Small proportions of externally recovered contaminated EPS that cannot be mechanically recycled.

As a company that has proudly operated with zero waste to landfill for several years, we are determined to ensure that no EPS goes to landfill and that we maximised the recycling potential of this valuable resource.

Solutions

To tackle these challenges, Springvale has invested in specialist EPS recycling equipment provided by our suppliers for many years now.

This on-site equipment allows us to:

  • Granulate clean EPS offcuts from our production lines and reincorporate recycled EPS directly back into our manufacturing processes, ensuring nothing goes to waste while maintaining the highest product quality.
  • Compress and send for external recycling any white EPS that our manufacturing capacity does not allow us to process, a very high percentage of grey EPS is used back into our process.
  • Collect and compress white and platinum dust particles to send for external recycling.
  • Operate a Customer Take-Back Scheme, providing a responsible route for our customers to return their clean EPS offcuts for recycling into new products or compress and send for external recycling.

We send only unrecyclable EPS to waste to energy recovery as a source of fuel, maintaining our zero to landfill commitment.

Additionally, we are actively seeking partnerships with specialist EPS recycling organisations to expand our recycling capabilities, particularly for returned material that has been contaminated.

Results

Zero EPS waste to landfill achieved and maintained for several years.

  • All EPS offcuts generated during production are recycled internally where capacity allows, with any surplus compressed and sent externally for recycling.
  • Recycling reduces raw material usage, cutting both costs and environmental impact.
  • A very high percentage of dust generated during manufacturing is captured, compressed, and sent externally for recycling.
  • Customer engagement with our take-back scheme is strong and continues to grow.
  • We are an active contributor to the circular economy in EPS manufacturing and construction sector.

We remain committed to going further. Our future plans include:

  • Partnering with external recycling specialists to maximise the recovery of all available EPS material, including contaminated material to reduce the quantity of valuable EPS diverted to waste-to-energy.
  • Any clean, externally recovered EPS that cannot be reused internally is to be compressed and sent externally for recycling.
  • Continuing to seek solutions that further reduce reliance on waste to energy, aiming to recycle as much EPS as possible.
  • Expanding customer participation in our take-back scheme to increase the volume of clean EPS returned for recycling.
  • Building partnerships with recycling organisations located closer to our customers to help lower the carbon footprint associated with transporting recovered material.
  • Supporting broader circular economy initiatives across the construction sector, contributing to a more sustainable built environment.

The future of EPS

Expanded Polystyrene (EPS) is an excellent choice for insulation, product protection, and a wide range of other applications. Remarkably, EPS consists of 98% air, meaning that only 2% of any finished product is actual polystyrene material.

With its outstanding thermal insulation properties, 100% recyclability, and strong circular economy potential, EPS is widely recognised as a first choice material in construction applications.

Using EPS can help reduce CO2 emissions by up to 50%, offsetting its small carbon footprint and delivering maximum environmental return for minimal resource use. Additionally, EPS insulation makes a significant contribution to reducing fossil fuel consumption for heating and cooling in buildings. This, in turn, helps lower SO2 and SO3 emissions, which are key contributors to acid rain.

Conclusion

At Springvale EPS Ltd, we believe sustainability is not an option – it is a responsibility. Through strategic investment in on-site EPS recycling equipment, ongoing personnel training, and close collaboration with our recycling partners and customers, we ensure that no valuable EPS material is ever sent to landfill.

We have extended this approach across all our waste streams, recycling all materials wherever possible. No materials are sent to landfill, and we continue to reduce our reliance on wase to energy.

As proud members of Operation Clean Sweep (OCS), we are fully committed to implementing measures that prevent pellet loss into the environment, reinforcing our dedication to environmental stewardship.

We continue to demonstrate leadership in responsible EPS manufacturing, and we are proud to play our part in building a cleaner, more circular future for the EPS and construction industries.