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EPS reliably protects sensitive technology - and at the same time places high demands on handling during operation. At Kilchenmann, we have been focusing on consistent separation and recycling for over 25 years. A look at processes, figures and the question of how responsibility is implemented in everyday life.
Expanded polystyrene, or EPS for short, is omnipresent in everyday life at AV, even if we do not actively use it ourselves. Many of the devices we receive are packaged with EPS by the manufacturers. The material reliably protects sensitive technology during transport and ensures that components arrive undamaged at our premises or directly to our customers.
This protection is particularly crucial for high-quality audio, video and communication technology. Damage during transportation not only leads to delays, but also to additional resource consumption due to replacement deliveries or repairs. This area of conflict makes it clear why EPS is still so widespread.
At the same time, handling this material is challenging from a sustainability perspective.
Handling at Kilchenmann
EPS is based on crude oil, is not biodegradable and can only be recycled properly in practice if it is collected separately. As we have no direct influence on the packaging used by manufacturers, we at Kilchenmann consciously focus on handling it in our own company.
Our handling of EPS has evolved over many years. While the material used to be disposed of as combustible waste - as was the case in many places - the development of an alternative solution began around 28 years ago. Since then, we have consistently separated and collected EPS and fed it into a recycling loop.
From waste to recyclable material
EPS from installations is returned, temporarily stored at the company and then regularly shredded on site. We use a special shredder for this, which prepares the material for the further recycling process.
The shredded EPS is collected in special recycling bags. As soon as a sufficient quantity has been reached, collection is organized. The material is then further processed by specialized partners and fed back into the EPS production cycle.
Clean separation is important here. Only unmixed EPS without foreign matter can be recycled efficiently. Materials with a similar appearance but a different composition must be consistently excluded.
Reusing the shredded material as packaging is not practical in everyday life. Due to its static properties and fine structure, it would get stuck in appliances and impair ventilation slots, for example.
Development of material quantities
The figures also show that this approach is having an effect. Compared to the previous year, the amount of EPS has been significantly reduced. While around 113,000 liters were still produced in 2024, this figure had fallen to 81,000 liters by 2025. This corresponds to a reduction of 28.3%.
This development is the result of a more conscious approach to material flows and the continuous optimization of internal processes.
Recycling as part of the overall system
The collected and processed EPS is further processed in specialized plants. There it is sorted, cleaned and processed into granulate. This granulate in turn serves as the starting material for new products, such as insulation materials.
In Switzerland, this cycle works very efficiently today. A large proportion of the material can be recycled and reused, reducing the need for new raw materials.
Economic efficiency and responsibility
In this context, sustainability also means considering economic aspects. The collection and recycling of EPS incurs costs, for example for recycling bags and logistics.
At the same time, it is clear that this effort is worthwhile. By switching to separate recycling at the end of the 1990s, we were able to significantly reduce the amount of waste disposed of with the regular refuse. This resulted in savings that exceeded the additional costs. In this case,
recycling is not only an ecological solution, but also an economically sensible one.
Limits and opportunities to influence
Nevertheless, the issue remains complex. Alternative packaging solutions are not always available or meet the same requirements for protection and standardization. Reliable packaging is crucial, especially for sensitive technology and international supply chains.
This makes it all the more important to use the levers where influence can be exerted. This applies to the internal organization as well as the exchange with partners and manufacturers.
Sustainability issues and optimization opportunities are regularly discussed in supplier meetings and are also included in our supplier evaluation.
A continuous process
The way we deal with EPS is a good example of how sustainability works in a technical environment. It is less about complete renunciation and more about a conscious approach to existing materials and processes.
For us, this means taking responsibility where we have a direct influence. At the same time, we monitor developments in the market and constantly check how processes can be further optimized.
This allows us to gradually develop a way of using materials that meets both technical requirements and ecological goals.
