Pollution Prevention Success Stories

TrueFoam, an Atlantic Canadian manufacturer of expanded polystyrene(EPS) insulation products and styropack shipping containers, was established in 1968 and has 95 employees. Truefoam produces rigid foam insulation without using ozone depleting substances such as chlorofluorocarbons (CFC) or hydrochlorofluorocarbons (HCFC) as expanding agents.

In the manufacture of EPS products, tiny beads of polystyrene are expanded and consolidated in a process of steam heating and pressure treatment. When heated, the expanding agent enlarges the beads as much as 40 times, after which they are fused by pressure into huge blocks of EPS. These blocks are cured, then cut and shaped to produce a variety of Truefoam sheet, board and panel products.

The polystyrene beads purchased by Truefoam contain pentane as an expanding agent. In 1998, Truefoam purchased new pre-expander equipment that allowed them to use beads containing 33% less pentane. Although the quantity of pentane in the beads is relatively small, the fully automated new equipment has resulted in lower pentane emissions and has also improved production efficiency. Pentane is a volatile organic compound and a contributing factor to smog.

In 1994, Truefoam installed a water cooling tower that allows them to recycle process cooling water, resulting in a 65% reduction in water use. They also attempt to reduce the production of waste trimmings by using molding equipment that has the flexibility to change dimensions to suit special products. They have also maximized the reuse of "trimmings" and other waste EPS generated by the cutting and shaping of the blocks into final products. For example, large "sticks" of polystrene, similar to 4x4 lumber, are used for product storage, smaller clean trimmings are ground back to bead size and reused in the production process.

As well, Truefoam’s product lines enable their clients to practice pollution prevention by assisting with energy conservation and product protection. Approximately half of its production is insulated shipping containers for fresh seafood and live lobsters. The energy efficient packaging (polystryene can use up to 30% less energy than paper equivalents) eliminates a great amount of waste due to spoilage of seafood products. Truefoam has developed shipping containers for every type and size of products from the ocean and the aquaculture industry.

As well, their line of insulation products allow better insulated buildings to be constructed without the use of extra materials. For example, TrueWall and InsulWall, designed by Truefoam, have incorporated molding options into the form design that reduce wood framing material requirements by 30 to 40%, as well as contribute to the energy efficiency of the building. A new product, introduced in 1997, Ice Block, an insulated concrete form will reduce concrete usage in building construction by up to 40% resulting in less construction resources being consumed, and more energy efficient buildings.

Truefoam is in its 34th year of manufacturing energy saving products in Atlantic Canada and continues to explore pollution prevention technology and design products to protect the environment.

• Truefoam replaced similar products which use CFCs and HCFCs with CFC and HCFC free rigid foams, contributing to reducing the impact of those chemicals on the ozone layer.
• 33% reduction in the amount of pentane (VOC) released to environment.
• Reduced waste materials such as trimmings by recycling it back into the process. 65% reduction in water use.
• The unique insulation products, Truewall, Insul-Wall and IceBlock, will place less demand on the environment for construction resources.

• The combined initiatives of water recycling and reduced pentane emission have been completed at a capital cost of close to $500,000. Truefoam estimates that these costs have been fully recovered.

• A greener community due to 33% reduction in VOC emissions.
• By reducing the impact on the ozone layer, there is a reduction in harmful UV rays.
• Funds received from recycling office paper, cardboard and drink containers goes towards a worker administered fund.