If you work in an industry that produces large amounts of EPS foam scrap, you’ve likely heard the terms “densifier” and “compactor” mentioned frequently. Both types of equipment are designed to reduce the volume of scrap EPS packaging blocks and boxes efficiently.
Manufacturers of EPS melting machines often refer to their equipment as EPS densifiers or thermal densifiers. On the other hand, those who make EPS cold compression systems with screw augers typically call them EPS compactors. Some companies that offer hydraulically driven systems may use either term. Regardless of the terminology, all three systems—screw, hydraulic, or thermal—compress lightweight foam materials into dense logs, bricks, patties, or ropes. Each type of machinery is capable of densifying and compressing various materials.
Understanding Densifier Machine Options
We’ve briefly touched on the different types of compression systems. Now, let’s delve deeper into screw, hydraulic, and thermal densifiers.
Screw-Type Densifiers/Compactor
Screw-type densifiers are ideal for compacting foam with a consistent density. These machines use augers to push foam through at varying speeds and pressure levels, depending on the volume of foam being processed. The result is compacted foam in the form of solid logs or blocks.
For instance, the Siedon compactor is a screw-type EPS densifier that efficiently densifies multiple types of foam using cold compression and screw-auger technology. This energy-efficient system uses external heaters to melt the exterior of the compacted log, encapsulating any non-binding materials for easier handling and storage.
Hydraulic Foam Densifier Machines
Hydraulic densifiers compress foam without using heat, eliminating concerns about chemical smells or smoke. These machines use hydraulic pressure to compress the foam and reduce its elasticity, making them capable of processing foams with varying densities simultaneously.
Thermal Densifiers
Thermal densifiers, as the name suggests, use heat to melt foam, which is then extruded and stored in containers. These densifiers can handle multiple types of EPS foams at once.
What Sets EPS Compactors Apart from Densifiers?
Now, to address the main question: What’s the difference between compactors and densifiers? While you might think they are completely different when it comes to EPS recycling, the terms are often used interchangeably. To ensure you choose the right equipment, focus on finding a machine that can handle your specific foam scrap and aligns with your recycling goals.
The Advantages of Using a Siedon Screw Compactor
At Foam Equipment & Consulting, we understand the need for effective and efficient foam recycling solutions. That’s why we offer Siedon screw compactors. These compactors are designed for long service life and low maintenance, helping businesses save on transportation and disposal costs.
Beyond these benefits, Siedon screw compactors also have advantages over thermal and hydraulic densifiers. Here are some drawbacks of using thermal densifiers:
The Drawbacks of Thermal (Melting) Compactors
Thermal densifiers are more susceptible to contamination and moisture during processing. Additionally, these systems consume more energy compared to screw-style compactors when processing expandable polystyrene. Thermal compactors also require a warm-up period, delaying the start of processing, while screw compactors can begin immediately.
Moreover, thermal compacting systems need ample ventilation due to the fumes generated from melting and burning the material. Screw compactors, on the other hand, do not require ventilation since nothing is melted, and there are no inhalation concerns.
Disadvantages of Hydraulic EPS Densifiers
Hydraulic densifiers can be prone to leakage and may require higher maintenance due to potential hydraulic valve failure. The Siedon screw compactor system, which uses only electrical drive components, avoids these issues. However, it’s important to note that not all screw compactors are hydraulic-free; some use hydraulic components to control the pressure flap density of the logs they produce, which can increase maintenance needs compared to a Siedon system.
Why You Can Rely on a Siedon EPS Compactor
Siedon stands as a leader in foam densification, known for its innovative screw press machine designs that surpass the limitations found in many other screw compactors. Siedon EPS compactors are engineered to be both robust and technically efficient.
Siedon screw compactors feature electrically driven, automatic density controls that adjust pressure to ensure consistent density in the compressed material. These systems are user-friendly, even for those with no prior experience. Our screw compactors are capable of producing high-density compressed logs of EPS and other materials while consuming minimal energy. Additionally, Siedon’s use of high-quality components means that their compaction systems require minimal maintenance and are renowned for their long service life.