Is EPS Bad for the Environment? An Honest Comparison with Honeycomb and EPP
Short answer: EPS is less bad for the environment than its reputation suggests: it consists of more than 98% air, is fully recyclable and has a low CO₂ impact in production. Honeycomb cardboard scores well on recyclability via waste paper, but production costs more water and energy and the insulation value is lower. In most analyses, reusable EPP wins: at 100+ use cycles, the impact per shipment is a fraction of both single-use options.
We get the question weekly: "isn't EPS bad for the environment?". In this article we set out the facts and figures, including the less favourable sides of honeycomb. Then we help you make a choice.
EPS: often misunderstood
EPS (expanded polystyrene, often called Tempex or styrofoam) has a bad reputation, mainly because of the volume in waste containers. But:
- EPS consists of >98% air. The actual material weight per cooler box is very low. Typically 100 to 300 grams of polystyrene for a box that cools several kilos of product.
- EPS is fully recyclable. Polystyrene can be melted down and reused for new products. The problem is logistics: there are still too few EPS collection points.
- EPS has a low CO₂ impact in production compared with some alternatives, partly because of the low material weight.
On top of that, EPS is lightweight and absorbs little moisture. A light box saves weight in transport. What that means exactly for your shipment depends on your route and volume.
Honeycomb cardboard: not always more sustainable
At first sight, honeycomb seems the sustainable choice, after all it goes into the paper container. But there are caveats:
- Production is energy-intensive. Making honeycomb cardboard takes considerably more water and energy than EPS.
- The insulation performance is lower. For the same temperature performance you sometimes need a thicker box, which partly cancels out the material advantage.
- FSC is important. Only FSC-certified honeycomb cardboard is actually produced sustainably.
Honeycomb remains a good choice for the right shipment, especially short webshop routes. View the honeycomb cooler boxes if you are considering this.
EPP: often the best environmental choice
EPP (expanded polypropylene) comes out best in most analyses, because of its reusability:
- An EPP box that is reused 100 times has a fraction of the CO₂ impact per shipment
- EPP is fully recyclable at the end of its life
- The service life in practice is often more than 5 years
The drawback: EPP costs 3 to 5 times more per piece than EPS. It is only interesting in return logistics or for parties that have control over the whole chain. A practical comparison is in EPS or EPP: which box do you choose, and you will find the range under EPP boxes.
Why reuse only works with a return flow
The advantage of EPP disappears if the box does not come back. A reusable box that stays with the recipient after one shipment is an expensive single-use box. Before you opt for reusable, it is sensible to arrange a few things in advance:
- Who brings the box back? Agree this with the recipient, preferably recorded in your agreements.
- How does the box come back? Return transport costs money. Include what that means per box.
- How do you clean and inspect the box? A damaged box insulates less well.
- How many boxes are on their way? A reusable box that is in transit cannot be filled. So keep enough stock.
With individual consumer shipments, such a return flow can usually not be organised. With regular B2B customers on a fixed route, it often works.
Which material suits which shipment?
| Situation | First choice to consider | Please note |
|---|---|---|
| Webshop, short transit time | Honeycomb or EPS | FSC for honeycomb, depending on transit time |
| Longer routes, higher insulation requirements | EPS | Choose the wall thickness to match the journey time |
| Fixed B2B route with return | EPP | Arrange the return flow in advance |
| Pharma with validation requirements | Usually EPS or VIP panels | Performance comes before sustainability |
This is a starting point. The actual choice depends on your product, the route and the outside temperature.
What does Cooled Solutions do?
We offer all three options and give honest advice on which suits your situation:
- For one-off B2C shipments (online butcher, meal box): honeycomb or EPS, depending on your brand preference and the transit time
- For closed chains or B2B: EPP for the highest sustainability
- For pharma with validation requirements: usually EPS or VIP panels. Performance comes before sustainability here
Our EPS boxes come from our own production since 1972. View our page on sustainability for our full vision, or contact us via our contact page for advice for your situation.
Frequently asked questions
Is EPS worse for the environment than cardboard?
Not automatically. EPS contains little raw material and insulates well. Cardboard can go into waste paper after use, but takes more water and energy in production. It depends on the shipment and on what happens to the box after use.
Is EPP the best for the environment?
In most analyses it is, provided the box is reused often. Without a return flow, that advantage disappears.
Where do I hand in an EPS box?
That differs per municipality and region. Read disposing of and recycling polystyrene foam: which bin does it belong in for an overview.
Is EPS suitable for foodstuffs?
EPS is widely used for packaging and chilled shipping of foodstuffs and does not absorb moisture or odour. We are happy to answer questions about conformity for your application.
Order directly
Need the right packaging straight away? View our EPS boxes, honeycomb cooler boxes, EPP boxes and our vision on sustainability.
