EPS is made by expanding polystyrene beads and molding them into shapes or blocks. Its low density makes loose packaging bulky to store and transport, even when the plastic itself weighs relatively little.

For recycling, EPS is usually kept separate from other foam types and checked for contaminants. Depending on the condition of the material and the intended output, a foam compactor can compress it into blocks, while a foam densifier can reduce its volume by melting it.