Polystyrene has an image problem. Despite being one of the most resource-efficient and recyclable packaging and construction materials available, it is frequently mischaracterised as wasteful, non-recyclable or environmentally harmful. These misconceptions persist partly because of confusion between different types of plastic, and partly because polystyrene recycling infrastructure was historically less visible than kerbside programs for bottles and cardboard.
Here we address five of the most common myths about polystyrene recycling, drawing on data from Australian industry bodies and our own experience operating closed-loop recovery programs.
Myth 1: Polystyrene Cannot Be Recycled
This is the most widespread misconception and it is simply incorrect. Both EPS (expanded polystyrene) and XPS (extruded polystyrene) are thermoplastics, meaning they can be melted and reformed repeatedly without significant loss of material properties. Clean post-consumer and post-industrial EPS is routinely collected, compacted, and reprocessed into new products.
At Hispatian, we operate compaction equipment at all five of our manufacturing sites. Production off-cuts are captured and recycled on-site, achieving near-zero manufacturing waste. We also collect clean EPS from construction sites and commercial customers through scheduled pick-up services.
Recycled polystyrene is reprocessed into a range of products including XPS insulation boards, picture frames, architectural mouldings, seed trays and other items — keeping the material in productive use rather than sending it to landfill.
Myth 2: It Takes Thousands of Years to Break Down in Landfill
While it is true that polystyrene is durable and does not biodegrade quickly in landfill, this is actually a positive characteristic from an environmental perspective. Polystyrene in landfill is chemically inert — it does not leach toxins into soil or groundwater, and it does not produce methane or other greenhouse gases as it decomposes (because it does not decompose).
Compare this to organic materials like food waste and paper, which decompose anaerobically in landfill and produce significant quantities of methane — a greenhouse gas approximately 25 times more potent than carbon dioxide. The real environmental priority is diverting organic waste from landfill, not polystyrene.
That said, the best outcome for polystyrene is recycling, not landfill. The material is too valuable and too easily recyclable to bury. Our industry's goal is to maximise recovery rates through better collection infrastructure and public education.
Myth 3: Polystyrene Manufacturing Is Highly Polluting
Polystyrene manufacturing is one of the least energy-intensive processes in the plastics industry. EPS is produced using steam — no solvents, no toxic chemicals, no heavy metals. The raw material (styrene monomer) is derived from petroleum, but the finished product is 98% air by volume, meaning a very small quantity of raw material yields a large volume of useful product.
Furthermore, when polystyrene is used as insulation, the energy saved by the building over its lifetime dwarfs the energy consumed during manufacturing — typically by a factor of 100 or more. The net environmental balance is overwhelmingly positive.
Myth 4: Nobody Actually Recycles It — There Is No Market
The market for recycled polystyrene is real, growing, and well-established in Australia. Industry programs such as Styrocycle, operated by the EPS Association of Australia, have built a national network of collection and processing sites. Major construction companies, packaging producers and councils participate in these programs.
Globally, recycled EPS is a traded commodity. Compacted EPS ingots are purchased by manufacturers for reprocessing into new materials. The economics of polystyrene recycling have improved substantially with the development of modern compaction and densification equipment, which reduces the bulk of EPS by a factor of 40 to 90, making transport cost-effective.
Myth 5: Alternatives Like Paper and Cardboard Are Always Better
Life cycle assessments consistently show that the environmental comparison between polystyrene and paper-based alternatives is more nuanced than public perception suggests. Paper production requires significant quantities of water, energy and chemicals (including chlorine bleaching agents). Paper-based packaging is heavier than EPS, increasing transport fuel consumption. And paper that is contaminated with food or moisture cannot be recycled — it goes to landfill where it decomposes and produces methane.
EPS packaging, by contrast, is moisture-resistant, lightweight and maintains its protective and insulating properties even when wet. For cold chain applications — transporting chilled food, pharmaceuticals and medical supplies — EPS outperforms paper and cardboard alternatives on every practical measure including thermal performance, durability and hygiene.
The right packaging material depends on the application. In many use cases, EPS is the more sustainable choice when full lifecycle impacts are considered.
Moving Forward
Polystyrene recycling in Australia is not a future aspiration — it is an established reality supported by industry investment, government partnerships and growing public awareness. At Hispatian Foam Solutions, we encourage all our customers and the broader community to participate in polystyrene recovery programs. Together, we can achieve higher recycling rates and ensure this valuable material continues to serve the circular economy.