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Foam is formed into logs

Fercell Heger Lion Foam compaction technology

What is your technology?

Fercell Heger Lion Foam compaction technology, in particular for the processing of cross-linked expanded polyethylene (EPE).

How does it work?

Production remnants are introduced into the loading hopper, which leads to a pre-breaker with two-toothed rotating shafts, reducing the input into pieces 20-50mm. These are forced by an auger into the pressure channel, where compacting begins automatically.

Once at maximum compression, heat is applied to smelt an external skin around the compressed log. The continuous log is dis-charged along a stainless steel channel for cutting to required length and pallet stacking in readiness for reprocessing.

Where would it ideally be used?

Wherever foam remnants are a production waste by-product. The compactor processes almost all types of foam, including EPS, XPS, EPP and EPE, easily and efficiently at the lowest energy cost to volume output levels, with reductions as high as 50:1.

How is it different?

This machine is probably the most flexible foam compactor available in the UK. When changing material type, a simple press of a button or touchscreen means production can commence quickly and without fuss. Up to 20 standard programmes are available, with bespoke ones offered for non-standard materials processing.

What benefits does it offer?

It offers fast return on investment, and also has low operation noise. It uses high- quality components and materials, to assist with reliability and machine life.

It offers two machine operations in one, with the inclusion of the pre-breaker.

Where it being used?

Construction, food, catering, marine, fishing, mouldings manufacturers, automotive, packaging manufacturers, foil manufacturers, recycling waste processors and appliance distributors.


An entry-level Fercell Heger compactor is available for less than £10,000. This model is most favoured by waste management companies with an on-site EPS collection contract.

Any savings?

The key area for savings is the weight to volume ratio reduction of up to 50:1 and greatly reduced transport costs. There is also reduced fire risk for the storing of some materials and simpler palletised SCM storage.

What about maintenance?

It has few moving parts and only two maintenance disciplines are involved: electrical and mechanical engineering.

For details visit:

Customer viewpoint: Manuplas

Before Manuplas invested in the Heger foam compactor, three skips of foam waste were going to landfill each week. The compactor has enabled us to reduce both the environmental impact and the removal and disposal costs associated with our foam waste. The compactor will enable Manuplas to make cost savings of up to £50,000 a year.

Vanden Recycling has recently taken eight pallets of compacted EPS foam and nine pallets of compacted PE foam logs. This has equated to 15 skips not needing to be sent to landfill and a saving of £6,000 in associated costs.

Manuplas currently has seven pallets of compacted foam on-site which a recycling company has shown interest in utilising. Dartmoor Zoological Park has also shown interest.

David Hamnett, research and development director

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