Recycling has become a defining factor in modern foam production and fabrication, driven largely by the rise of the sustainability-minded consumer.
“Today’s consumers are searching for accessible, affordable, and environmentally responsible services and products,” wrote Lyudmil Karavasilev for The Reynolds Center for Business Journalism. “In turn, companies are being challenged – and inspired – to reimagine product design, delivery, and impact in ways that align with these expectations.”
Foam producers and fabricators are rising to meet that challenge. Trade associations for the expanded polystyrene (EPS) industry report that EPS packaging recycling rates in North America have reached approximately 30 percent, supported by expanded drop-off programs and alternative recycling channels. When recycled scrap foam generated during fabrication is included, annual foam recycling volumes now approach 200 million pounds.
In 2025, manufacturers are judged not only by the quality of their products but by how responsibly they produce, reuse, and reintegrate materials into the supply chain. According to recent GlobeScan data, 49% of Americans purchased an eco-friendly product last month, up from 43% in July 2024, reflecting how sustainability has become a mainstream expectation shaping purchasing decisions across industries.
Foam materials such as expanded polystyrene (EPS), polyurethane (PU), and polyethylene (PE) remain essential in construction, packaging, insulation, and protective applications. Yet their lightweight, durable nature presents long-term environmental challenges when waste is not managed responsibly. As landfills face growing pressure, transportation costs rise, and carbon reporting becomes more common, recycling has evolved from an optional initiative into both an environmental responsibility and an operational advantage.
At Sterling Manufacturing and Distributing, recycling is an integral part of how we approach foam production and fabrication. From material selection to scrap recovery and reintegration, our processes are designed to minimize waste and maximize efficiency. Our continued investment in recycling technologies reflects a simple belief: sustainability and manufacturing performance should move forward together.
Looking to 2026, recycling in foam production is shifting from a behind-the-scenes operational practice to a visible differentiator for manufacturers and fabricators.
Customers increasingly expect transparency around material sourcing, recycled content, and emissions reduction. At the same time, manufacturers face rising disposal costs, supply chain volatility, and growing pressure to document sustainability progress. These forces are accelerating investment in recycling infrastructure, closed-loop material flows, and partnerships that support measurable environmental outcomes.
For foam fabricators, this means recycling programs must do more than divert waste. They must support consistent quality, reliable supply, and efficient fabrication while contributing to broader sustainability goals. Companies that integrate recycling into day-to-day operations are better positioned to meet customer expectations, manage costs, and adapt to evolving market demands.
This outlook reinforces why recycling has become foundational to responsible foam production and fabrication rather than an optional add-on.
Foam products can take hundreds of years to decompose in landfills, contributing to long-term waste accumulation if not carefully managed. Recycling plays a critical role in reducing landfill dependency while conserving valuable raw materials and energy.
As sustainability expectations increase, foam producers and fabricators are taking proactive steps to minimize waste and reduce their environmental footprint. Beyond the environmental impact, these efforts also strengthen supply chains by lowering reliance on virgin materials and improving overall production efficiency.
At Sterling Manufacturing, disciplined recycling programs make this commitment measurable. Today, Sterling recycles approximately 95 percent of all fabrication by-products, keeping valuable EPS, PU, and PE materials in circulation. This closed-loop approach not only diverts waste from landfills but also ensures consistent product quality and performance across every manufacturing process.
Recycling delivers both environmental and economic advantages across foam production and fabrication operations. By transforming post-production scrap and end-of-life materials into usable resources, manufacturers can create more efficient, sustainable processes that support long-term growth.
Key benefits include:
As recycling technologies continue to advance, these advantages will only deepen, enhancing both environmental performance and operational efficiency.
Sterling Manufacturing operates comprehensive recycling programs across all major foam types (expanded polystyrene (EPS), polyurethane (PU), and polyethylene (PE)), ensuring that fabrication by-products are repurposed whenever possible.
Sterling recycles EPS scrap in two primary ways: by grinding and using it as stuffing for toys and bean-bag furniture or reintegrating it into raw-material production processes. This reduces waste while supporting new product applications that keep EPS in circulation.
PU by-products are shredded for carpet padding underlayment and rebonded for gym flooring and gymnastics mats. These durable, high-performance uses highlight how fabrication waste can be transformed into valuable second-life products.
PE scrap is either returned to raw-material producers or converted into film products such as 4-mil black construction bags. This closed-loop process ensures polyethylene waste is fully utilized within broader manufacturing channels.
Sterling’s sustainability efforts extend beyond foam. Corrugated cardboard is baled and sent to paper recyclers, while wood pallets are reused internally, repurposed for outbound freight, or sent to pallet recyclers. By addressing multiple waste streams, Sterling reduces environmental impact across every stage of fabrication and distribution.
Effective foam recycling relies on proper handling at every stage:
These steps maintain product integrity while minimizing waste across the fabrication cycle.
Sterling’s recycling leadership earned national recognition in 2024 with the Pregis Renew Award. Through the supply of Pregis Renew™ solutions made with recycled content, Sterling helped customers collectively reduce more than 100 metric tons of carbon emissions in one year.
That reduction is equivalent to:
These measurable results reflect the tangible environmental impact of comprehensive foam recycling initiatives.
Recycling is now a strategic cornerstone of modern foam production and fabrication. It enhances environmental stewardship, operational efficiency, and customer confidence.
By continually refining recycling practices and collaborating with sustainability-focused suppliers, Sterling Manufacturing and Distributing remains committed to reducing waste, lowering emissions, and delivering consistent, reliable foam solutions.
Contact Sterling Manufacturing and Distributing today to learn how our recycling-driven approach can support your goals in 2026 and beyond.