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Save space on foam waste

What is the product?

Expanded foam screw compactor from Fercell.

How does it work?

At entry level, there is a manually fed hopper system. On the larger turnkey type, high-volume installations material input feed is via conveyor. Next, a pre-breaker with toothed rotating shafts reduces the material into 20-50mm pieces. With up to a 50:01 compaction rate, output square block ‘logs’ are continuously discharged from a stainless steel pressure channel to be broken into suitable lengths for palletising and wrapping.

Where it would ideally be used?

Either at the waste stream source, creating a new revenue income stream, or a transfer station specialising in foam waste management.

How is it different?

All built-in drives are driven by electrical motors. The modular concept makes it possible to implement individual application compliance. The pressure channel is made of V2A stainless steel, and is able to process moist foamed packages without leaving traces of rust on the surface. A switch cabinet includes a control unit and touchscreen technology.

What are the benefits?

Benefits include enormously reduced storage, transport and disposal costs. Most compacted foam plastic material has now found a valuable secondary commodity market and can be recycled or downcycled. More effective processes in waste management save valuable human resources.

Where has it been used?

Applications include coffee vending; TV and computer screen component packaging; fruit and fish boxes; white goods product packaging returns; and waste transfer stations specialising in expanded foams.


The expanded polyethylene foam standalone entry-level machine is a Tiger 130T mobile foam compactor for less than £10,000. It is delivered pre-commissioned and ready to go, requiring only electrical connect to start production.

It has a throughput of 10-15kg an hour, achievable density is 200-500kg/cu m and block log dimension is 130 x 130mm.

Any savings?

Drastically reduced transport costs, lower storage requirement and industry accepted recyclate format. One UK manufacturer recovered the initial cost of the machine within a year.

What about maintenance?

Robust engineering and drives with few moving parts ensure long productive operation intervals between maintenance shutdowns. Parts are off the shelf from our UK facility, offering rapid next-day service. The mechanical design is uncomplicated, and operator and maintenance technician training is included in the purchase price.

What is its lifespan?

There are many variables, but our longest-serving installation is more than 10 years old.

Any future applications?

A recent development is the Crocodile dewatering system based on the auger principle, which removes residual fluids from waste material.

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