Plastics pollution is a serious global challenge that requires practical, science-based solutions. Extended Producer Responsibility (EPR) legislation has emerged as a key policy mechanism to address packaging waste by shifting end-of-life responsibility from municipalities to producers. As EPR laws continue to expand across the United States, it is critical that policy decisions be informed by material performance, environmental tradeoffs, and real-world recycling outcomes—particularly for transport packaging.
Expanded Polystyrene (EPS) plays a critical role in both protective packaging (such as major appliances, electronics) and cold chain packaging (including food and pharmaceuticals). EPS provides strength-to-weight ratios, superior shock protection, and excellent thermal insulation while using significantly less material by weight than many alternative packaging formats. In numerous applications, EPS reduces total packaging weight by 50–70%, which translates directly into lower transportation emissions and reduced overall environmental footprint.
Contrary to common public perception, EPS is highly recyclable, particularly through mechanical recycling, which requires only electricity and heat, uses no chemical solvents, and represents the most environmentally favorable end-of-life pathway for EPS. Mechanical recycling enables used transport packaging to be converted back into polystyrene resin for new EPS products. EPS molded with 30–50% recycled content performs equivalently to virgin EPS in terms of compression strength, impact resistance, and thermal performance making circularity technically viable today.
The primary recycling challenge for EPS is not recyclability, but collection and logistics, due to its lightweight and bulky nature prior to densification. In response, the EPS industry—working through manufacturers, resin suppliers, recyclers, and associations—is investing in expanded collection, densification, and recycling infrastructure, with the goal of providing EPS recycling access to over 60% of the U.S. population. Early results from regional pilot programs and industry-funded initiatives demonstrate meaningful progress.
EPR legislation is now in effect in seven U.S. states: California, Colorado, Maine, Maryland, Minnesota, Oregon, and Washington, with additional states actively considering similar laws. Importantly, no state has enacted a ban on EPS transport packaging. Instead, EPR frameworks focus on improving recycling rates, incorporating post-consumer recycled content, and incentivizing better material design through eco-modulated fee structures. Current data indicates that EPS transport packaging recycling rates are already in the mid-20% to low-30% range, placing EPS on a realistic pathway to meet near-term EPR recycling targets, including California’s 30% mandate by 2028.
As EPR programs mature, EPS transport packaging is well-positioned to succeed. In several states, the fees being collected by the state through their designated Producer Responsibility Organizations (PROs) are expected to be used to help fund the expansion of EPS recycling infrastructure. In addition, the structure of eco-modulation programs in some states provides opportunities for producers of EPS transport packaging to reduce their fees based on the work done by producers to recycle EPS through direct business-to-business arrangements.
Overall, continued progress will depend on collaboration among brand owners, manufacturers, recyclers, regulators, and NGOs—and on ensuring that policies are driven by data, life-cycle science, and practical implementation rather than material misconceptions. When evaluated holistically, EPS remains an environmentally responsible and essential packaging solution within a circular economy framework.
Written by Joe Grzyb, Director of Sustainability.
Joe Grzyb (pronounced “Gribb”) has over 25 years of experience in leading, managing, and growing high-tech companies primarily in the temperature-controlled packaging industry. Joe was a Co-Founder of NatureKool® and he now joins EFP as our first-ever Director of Sustainability. Before joining EFP, Joe held positions such as Founder of Aspen Technologies, CEO of Phase Change Energy Solutions, and leadership roles at AmeriTech Exports, ITT Defense and the US Air Force.
