Business Idea: Manufacturing and Selling Styrofoam

Business Ideas & Inspiration Manufacturing Business Ideas 06.08.2014  0 97 0
Business Idea: Manufacturing and Selling Styrofoam

💡 Want more business insights? Stay ahead of the curve with our exclusive updates!

👉 Join our Telegram channel for daily business ideas and expert tips.

👉 Follow us on Facebook to never miss a trend or update!

Don’t just read—connect, grow, and innovate with us today!


One of the truly lucrative businesses in the manufacturing sector is producing foam plastic. Due to its high profitability, this business can start yielding returns within just a couple of months.

Foam plastic is a lightweight material with low density and excellent sound and thermal insulation properties. Its demand is quite high today, widely used in construction, trade, healthcare, shipbuilding, and as a packaging material.

Business Idea: Foam Plastic Production and Sales

Key criteria when using foam plastic in households are its eco-friendliness, safety for human health, practicality, long shelf life, and resistance to environmental factors. Expanded polystyrene foam boasts the best characteristics. It consists of white bead-like foam balls compressed together, is durable, does not emit toxic vapors under normal conditions, and does not promote mold or algae growth.

Production Technology

The process of manufacturing this material involves several steps:

  1. Raw material foaming (once or multiple times to achieve the desired density) in a special pre-foaming unit;
  2. Aging to dry the foam plastic and stabilize pressure inside the polystyrene beads (takes 12-24 hours);
  3. Molding, during which the beads expand and fuse into a homogeneous solid entity under steam pressure;
  4. Secondary aging (takes 24 hours);
  5. Cutting the foam plastic according to required sizes and shapes.

Business Idea: Foam Plastic Production and Sales

Raw Materials

In the production of expanded polystyrene foam, expanded polystyrene (EPS) granules are used as raw material. The cost of EPS granules varies depending on the fraction and manufacturer, averaging around $1.7-1.9 per 25 kg pack. Opting for a domestic manufacturer can reduce raw material costs, while imported ones can enhance productivity by nearly 10% due to better granule expandability. Most foam plastic manufacturers use Chinese raw materials, prioritizing production efficiency over cost savings.

Business Idea: Foam Plastic Production and Sales

Equipment

Foam plastic production utilizes the following components (with approximate costs listed):

  • Pre-foaming unit – $4500;
  • Secondary foaming apparatus – $800;
  • Steam generator – $1600 (can be liquid or solid fuel-based);
  • Mold – $2700 each;
  • Drying and aging fan – $350;
  • Cutting table – $780;
  • End trimmer – $750;
  • Crusher with ventilation – $1100;
  • Steam accumulator – $1700.

While this equipment is relatively simple to install and maintain, certain nuances can significantly impact foam plastic production costs.

Firstly, it is advisable to use a steam generator running on liquid or solid fuel. Additionally, you can enhance this unit with a special boiler and waste disposal system, making production waste-free, reducing fuel costs, and boosting boiler productivity up to 2.5 times.

Business Idea: Foam Plastic Production and Sales

A steam boiler with a waste disposal system costs from $4900. Experience from many successful entrepreneurs in this field shows that costs can be easily recouped within a few months. However, this equipment requires appropriate maintenance personnel – one or two boiler operators will suffice. Most importantly, the boiler must be placed according to safety regulations in a separate room.

Business Idea: Foam Plastic Production and Sales

If such facility is not available, electric boilers can be used. Although their cost (ranging from $1800 to $2500) is lower, electricity expenses can significantly increase foam plastic costs, reducing profitability.

Secondly, one molding unit may not be sufficient. Entrepreneurs commonly use a minimum of two units in production. Managing this unit will require a small staff of one or two individuals.

Business Idea: Foam Plastic Production and Sales

If you plan high-volume foam plastic production, consider investing in a table with an electric cutter, costing around $7800-7900.

A crusher will aid in rational use of raw materials and waste. It allows recycling foam plastic scraps, shredding them for reintegration into the pre-foaming unit.

Resources and Materials

It's important to note that besides raw materials, water, electricity (especially with electric boilers), and steam will be required for production.

In addition to monthly expenses, consider adding:

  • Space rental costs;
  • Company setup expenses;
  • Accounting costs;
  • Taxes (on employee salaries, based on chosen tax system);
  • Transport rental expenses;
  • Fuel costs;
  • Driver wages.

The last three items should only be considered if you plan to distribute finished products to stores or construction sites.

Business Idea: Foam Plastic Production and Sales

Cost and Profit

With the mentioned equipment and considerations, it is realistic to produce up to 52 cubic meters of expanded polystyrene foam per day.

The production cost of 1 cubic meter of foam plastic is $0.85. The retail selling price depends on the foam plastic density. On average, 10 cubic meters sell for about $350. Deducting utility payments, salaries, space rental, net profit can easily reach $2600-2700 per month.

Advantages of the Business Idea:

  • Simple production process;
  • Affordable raw materials;
  • High profitability;
  • Quick return on investment (2-3 months);
  • Requires a relatively small initial capital to start the venture;
  • High and stable product demand.

Business Idea: Foam Plastic Production and Sales

💡 Want more business insights? Stay ahead of the curve with our exclusive updates!

👉 Join our Telegram channel for daily business ideas and expert tips.

👉 Follow us on Facebook to never miss a trend or update!

Don’t just read—connect, grow, and innovate with us today!


06.08.2014  0 97 0
Construction & Building Materials Business Ideas Manufacturing Business Ideas
Business Ideas & Inspiration
производство бизнес идея пенопласт
New business ideas

Note: Comments are being moderated and may take a while to appear. There is no need to resubmit your comment.

How to Start Real Estate Investment: Lessons from Keith Wasserman 316
The Best and Worst Business Ideas to Start in 2025 301
How to Make Money with Stock Photos and Videos in the Age of AI: A Step-by-Step Guide 293
10 Businesses Under $100 to Start in 2025 with Million-Dollar Potential 280
How to Use Your Stimulus Check 2025 to Start a Business 259
Today Everyone Uses Canva, but Who Created It? 246
DeepSeek: The Chinese AI Challenging ChatGPT and Reshaping the AI Landscape 237
How to Earn Money with ClickBank: A Complete Beginner's Guide 234
Hyper-Personalization: Boost Sales with Technology 234
How a Young Entrepreneur Made $2.7M with Affiliate Marketing 219
How to Earn by Providing Services to Immigrants in 2025 216
Is It Worth Starting a Business on TikTok for Americans in 2025? 213
How to Earn with Coloring Books on Amazon KDP 208
How to Build a Million-Dollar Online Business: A Step-by-Step Strategy 204
Artificial Intelligence (AI) Certifications to Boost Your Career and Earnings in 2025 203
6 Netflix-Based Business Ideas That Work 199
Vending Machines: Farm Products, Pet Supplies, and Cosmetics 199
How to Make $1,000+ Per Month Selling eBooks: A Step-by-Step Guide 195
How to Make $780/Day with Google Trends and AI: Step-by-Step Guide 194
50 Ways to Save $50 a Month: Updated for the Modern World 186
Top Free Video Editors for YouTube Creators in 2025 163
Luis von Ahn: The Innovator Who Revolutionized Language Learning 160
Pet Care Services (Dog Walking and Pet Sitting) 157
How to Start Investing in Rental Properties and Build Passive Income 153
Nostalgic Marketing: How to Use the Power of the Past to Boost Sales 95
How to Build a House for $250: Practical Guide 141
Make Your Own Furniture Using Old Tires 281
Gift Jam: A Sweet Business Venture 160
The First Lady's Porcelain Artist 154
Fascinating Facts from the History of the Largest Hosting Provider, Digital Ocean 151
Mark Shuttleworth: Internet, Space, and Ubuntu 151
Fascinating Facts About Shutterstock 173
Amazon Bestseller: Doona Infant Car Seat & Latch Base – The Ultimate Stroller-Transformer 787
Amazon Bestseller: Sugru Moldable Glue – The Flexible Fix for Any Project 201
Foot Hammock: A Simple Solution for Leg Fatigue 175
Construction Using Primitive Techniques 261
The Future of Medicine: Israel's Breakthrough in 3D Printing and AI for Drug Development 210
Olga Vidischeva and Her Boutique Aggregator Shoptiques 243
Plastering Station with Daily Income of up to 20,000 Rubles 179
Turning Treasure Hunting into a Profitable Business Venture 237
Seaweed Bottles 210
Real Business for Real People! 279
15 Unique Inventions That Can Simplify Life 238
Creating a Scrap Metal Recycling Center: A Business Idea 231
Scooter vending 244
Top 5 Devices and Technologies That Will Soon Make History 235
Exciting Business Idea: Exhibition and Sale of Live Tropical Butterflies 249
TeslaMotors: A Business Idea Set to Revolutionize the Automotive Industry 210
Eco-Friendly Furniture Made From Mushrooms 258
Microgrids: The Future is Here! 195