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PSE reliably protects sensitive equipment—while setting high standards for handling within the company. At Kilchenmann, we have been committed to consistent sorting and recycling for over 25 years. A look at the processes, the figures, and how responsibility is put into practice on a daily basis.
Expanded polystyrene, or EPS, is ubiquitous in our daily work at MO, even though we don’t actively use it ourselves. Many devices we receive are packaged in EPS by the manufacturers. This material reliably protects sensitive equipment during transport and ensures that components arrive intact at our facility or directly at our customers’ locations*.
This protection is particularly crucial for high-quality audio, video, and communication equipment. Damage incurred during transport not only causes delays but also leads to additional resource consumption for replacement shipments or repairs. It is in this challenging context that we understand why EPS remains so widespread.
At the same time, handling this material poses challenges in terms of sustainability.
Manipulation at Kilchenmann
EPS is petroleum-based, non-biodegradable, and, in practice, is only recycled effectively if it is collected properly and separately. Since we have no direct influence over manufacturers’ packaging, at Kilchenmann we consciously start by managing it within our own company.
Our approach to handling EPS has evolved over many years. Whereas the material was previously—as in many places—disposed of with combustible waste, the implementation of an alternative solution began about 28 years ago. Since then, EPS has been systematically sorted, collected, and recycled at our facility.
From waste to recyclable material
EPS from our facilities is recycled, temporarily stored on-site, and then regularly shredded on-site. We use a special shredder for this purpose, which prepares the material for the next stage of the recycling process.
The shredded EPS is collected in special recycling bags. Once a sufficient quantity has been reached, a collection is organized. The material is then processed by specialized partners and reintroduced into the EPS production cycle.
It is important to ensure proper separation. Only pure EPS, free of foreign substances, can be recycled effectively. Materials that look similar but have a different composition must be systematically excluded.
Reusing shredded material as packaging is not advisable in everyday use. Due to its static properties and fine structure, it would get stuck in appliances and, for example, block ventilation slots.
Changes in Material Quantities
The figures also show that this approach is effective. Compared to the previous year, the amount of PSE has been significantly reduced. While there were still approximately 113,000 liters in 2024, by 2025 this figure had dropped to just 81,000. This represents a reduction of 28.3 percent.
This development is the result of more conscious management of material flows and continuous optimization of internal processes.
Recycling as part of the overall system
The collected and prepared EPS is processed in specialized facilities. There, it is sorted, cleaned, and transformed into pellets. These pellets, in turn, serve as raw material for new products, such as insulation materials.
In Switzerland, this cycle now operates very efficiently. A large portion of the materials can be recycled and reused, which reduces the need for new raw materials.
Profitability and Responsibility
In this context, sustainability also means taking economic factors into account. The collection and recycling of EPS involve costs, such as those for recycling bags and logistics.
At the same time, it turns out that these efforts are worth it. As early as the late 1990s, the switch to separate recycling allowed us to significantly reduce disposal via regular household waste. This has resulted in savings that exceed the additional expenses.
In this case, recycling is not only an environmentally friendly solution, but also an economically sound one.
Limits and opportunities for influence
The issue remains complex, however. Alternative packaging solutions are not always available or do not meet the same requirements for protection and standardization. Reliable packaging is particularly crucial for sensitive technologies and international supply chains.
It is therefore all the more important to use the available levers of influence wherever possible. This applies to both internal organization and interactions with partners and manufacturers.
Thus, sustainability issues and opportunities for optimization are regularly addressed in discussions with suppliers and are also taken into account in our supplier evaluation.
An ongoing process
The processing of PSE is a prime example of how sustainability works in a technical context. It is less about completely doing without and more about the conscious use of existing materials and processes.
For us, this means taking responsibility where we have direct influence. At the same time, we monitor market developments and continuously examine how to further optimize processes.
This is how, step by step, a materials management system emerges that meets both technical requirements and ecological goals.
