Foam Recycle Program – 1 Year Anniversary

The beginning of February marked the one year anniversary of our foam recycling program. In that time we reused or recycled 2412 cubic feet of foam. That’s two tons of waste saved from the landfill! According to, 60 million tons of polyethylene foam is produced annually world wide. So we have saved .0000033% of the worlds foam polyethylene foam from entering the waste stream. When you look at our contribution as a percentage of the whole it’s just a drop in the bucket, but it’s a start. We know you’re thinking that it’s a small contribution, but let’s look at it in another way:

2412 cubic feet of foam is roughly equal to:

2,038,884  ping pong balls

110,616 Big Macs (our engineers favorite of course)

16,033  12-packs of beer (pairs well with the Big Macs)

9,614  basketballs


1  school bus

Foam Recycling Program

As a manufacturer of environmentally friendly products, it is always our goal to find new ways to be even more green in our business practices. In January 2009 we decided to implement a foam packaging recycling program to help reduce our environmental impact. Packaging_reduced

In order to ensure that our fans reach customers throughout the country without damage, they require robust polyethylene foam packaging. Polyethylene is a highly elastic and strong plastic that can withstand multiple impacts, making it ideal for shipping heavy objects such as whole house fans. Unfortunately, both the production and disposal of polyethylene, like all plastics, causes serious damage to the environment. In many parts of the country polyethylene foam is difficult if not impossible to recycle, so most of it ends up in a landfill.

The only way to reduce the hazards of plastic is to reduce the production of new plastic products. This is done by both decreasing overall demand and increasing the recycling of plastic. Our program allows us to reduce our need for the production of new polyethylene and also reduce the total amount of plastic being thrown away. We reuse the foam as many times as we can and then we recycle it, ensuring that the foam returned to us does not end up in a landfill.

It is immensely satisfying to us that we have had great customer response to this program. Almost 1 year  into the program and we have an average return rate of 42%, and the numbers are constantly increasing! My personal goal is to achieve a 50% return rate by next Spring, and with the return rates always increasing, I believe we can easily achieve this goal.

We owe a big thank you to all of our customers who have supported this program. We would also like to send out a hearty thanks to UPS, who has kindly begun waiving label printing fees and also begun offering us a discount on our return packages. With the help of UPS, our foam recycling program has been made more financially viable for us to continue in the future.