Are Polystyrene Boxes a Sustainable Food Packaging Solution?

Polystyrene boxes (EPS) are often unfairly labelled as environmentally unfriendly. The reality is very different. At JB Packaging, sustainability has always been a core concern, and EPS continues to prove itself as one of the most resource-efficient food packaging options available today.

How Are Polystyrene Boxes Made?

The manufacturing process for Expanded Polystyrene (EPS) is remarkably simple and environmentally considerate. It uses only water, steam, and pressure to fuse tiny beads together into strong, lightweight packaging. No harmful by-products are released, and the process is energy-efficient with minimal waste.

In fact, EPS packaging relies on the most abundant and environmentally friendly material in the world fresh air. EPS is 98% air and just 2% polystyrene, which is what gives it its strength and insulating ability while remaining extremely lightweight.

What About the 2% Polystyrene?

The small amount of polystyrene in EPS is derived from styrene a by-product of crude oil refining. Styrene occurs naturally in many foods including strawberries, nuts, beans, coffee, and even wine and cinnamon. Far from being exotic or harmful, styrene is part of our natural environment.

100% Recyclable and Reusable

Clean EPS is fully recyclable, and thousands of tonnes are recycled across Europe every year. At JB Packaging, all manufacturing scrap is recycled on-site and fed back into production. The UK EPS industry actively promotes recycling through initiatives with the EPS Packaging Group.

Recycled EPS can be used to create a wide range of new products, such as:

  • Picture frames
  • Coat hangers
  • Hardwood decking
  • Garden furniture
  • CD and DVD cases

Environmental Benefits of EPS

  • Lightweight: Reduces fuel consumption and carbon emissions during transport
  • No harmful gases: Contains no CFCs, HFCs, or toxic by-products
  • Recyclable: Rejects and off-cuts can be reground and reused
  • Protective: Superior insulation reduces food waste in transit
  • Inert and safe: EPS does not leach chemicals or release pollutants
  • Energy recovery: If not recycled, EPS can be safely incinerated as a clean fuel source
  • Landfill stability: If disposed of, EPS is inert and does not break down into harmful liquids or gases

EPS in Protective Packaging - What the 2025 TNO Study Shows

Recent independent research by the Netherlands Organisation for Applied Scientific Research (TNO) has compared the lifecycle climate impact of different protective packaging materials including expanded polystyrene (EPS), expanded polypropylene (EPP), corrugated paperboard, and moulded pulp  for televisions and washing machines.

The study found that EPS consistently produced the lowest overall climate impact per product delivered intact. While paper- and pulp-based alternatives may appear favourable at first glance, their higher transport emissions, bulk, and greater risk of damage to goods meant they performed worse when looking at the full delivery system.

This matters because the environmental cost of product damage far outweighs the footprint of packaging itself. If a washing machine or television is damaged in transit, the energy, raw materials, and carbon tied up in that product are wasted  and replacements increase emissions further. Packaging that prevents damage has the lowest overall footprint.

Even at a 40% recycling rate, EPS outperformed cardboard and moulded pulp packaging with a 100% recycling rate. In the washing machine scenario, EPS reduced total CO₂ emissions by up to 35% compared to cardboard.

Conclusion: Where protective performance is critical to preventing waste, EPS offers one of the strongest lifecycle sustainability profiles of all tested packaging materials.

Why do our Customers Choose EPS Packaging?

The message from the TNO 2025 study is clear: when it comes to protecting valuable goods in transit, the sustainability of packaging cannot be judged on material identity alone. What really counts is whether your products arrive intact. Every damaged shipment means wasted energy, wasted resources, and disappointed customers.

For JB Packaging’s customer base whether you’re shipping fresh seafood, temperature-sensitive foods, pharmaceuticals, or specialist products EPS packaging consistently delivers the best balance of protection, efficiency, and sustainability. Its insulating properties reduce spoilage, and its proven durability prevents costly product losses. Add to this the fact that EPS is 100% recyclable, and it becomes clear why so many industries continue to trust EPS for their cold chain and protective packaging needs.

FAQ – Polystyrene & Sustainability

Q: Is EPS safe for food packaging?
A: Yes. EPS is non-toxic, inert, and widely approved for use in food and pharmaceutical packaging. (Source: Food Standards Agency)

Q: Can EPS really be recycled?
A: Absolutely. EPS is 100% recyclable when clean and is reused in the UK and across Europe to create new everyday products. (Source: EPS Packaging Group)

Q: Is EPS worse for the environment than cardboard?
A: No. While cardboard is biodegradable, EPS is lighter, requires less energy to produce, and prevents food waste by offering superior insulation. Food waste is a major source of carbon emissions, so reliable protection is crucial. (Source: WRAP UK)

Want to know more about EPS and recycling? Visit our FAQs or call us free on 0800 285 1339.

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