ROADWAY Expanded Polystyrene Material Recycle System

We use CP solvent to dissolve expanded polystyrene in a way that is friendly to both people and the environment. The Roadway System: expanded polystyrene recycling with zero emissions of smoke, odors or wastewater.
No burdens at all placed on the environment.

Expanded polystyrene is dissolved with CP solvent to create raw material, which is used at the recycling plant to make new plastic products. It is then passed on to the consumer.
In this complete recycling system, waste is not only recovered, recycled and reused, but also the use of the Earth’s natural resources is minimized. It is an environmentally friendly recycling system.
CP solvent is used to convert the waste expanded polystyrene to the plastic raw material. It is processed at room temperature, without the need for fire or water. No smoke or wastewater is produced, diminishing the effects on people and the environment. It is also comparatively safe in the unlikely event that substances should enter the body. The CP solvent is recycled and reused, ensuring lower costs.

Features of CP Solvent Recycling

■CP solvent is very safe, ensuring that processing is also very safe.
■Processing has no effect at all on the surrounding environment, contributing greatly to the prevention of environmental damage.
■It is compressed by 1/50 to 1/100 at the location where the waste is produced, so the transport efficiency is high.
■Heat is not used in the compression process, and the molecular structure is not changed, so the waste can be made into a high quality polystyrene raw material.
■Only the expanded polystyrene is dissolved, so solid or oil foreign matter is easy to eliminate.
■The gel raw material is processed at the recycling plant to produce polystyrene chips for reuse.
■The raw material of the CP solvent is oil, the same as polystyrene. However more than 95% is recovered and recycled at the recycling plant, making it an environmentally friendly product.
■With a high recycling ratio of around 100%, it has excellent energy conservation qualities.

CP Solvent: A very safe shrinking agent.

Main raw material supplier I INVISTA Co., Ltd.
Principal component 1 Ester synthetic oil
Volatility I Extremely low
Classification 1 Fourth group, third oil type (under Japanese fire prevention laws) Gel classification (Gel = dissolved substance after processing) I Non-hazardous material By-product gas 1 None
Flash point 1 100°C (Gel flash point: 107°C)
Fire point 1 370°C
Dissolving ratio I Expanded polystyrene 1 kg: CP solvent 1.2 kg *Guaranteed values

Comparison with Other Solvent Manufacturers

Roadway System
(CP Solvent)
Competing Solvent
Fire Prevention Law Fourth group, third oil type (hazardous material handling level: low) Fourth group, second or first oil type (hazardous material handling level: high)
Volatility Virtually non-volatile. Volatile.
Odor Slight odor, but non-volatile so not pervasive. Produces an odor. / Volatile, so easily becomes pervasive.
Flash Point Solvent developed with a high flash point of 100°C, with an emphasis on safety of processing workers. Most have a low flash point of around 14°C to 50°C, so caution necessary in indoor processing and storage management.
Storage For the third oil type, a fire prevention law notification is not necessary up to 400 liters. For the second oil type, a fire prevention law notification is necessary for 200 liters or more.
Gel storage and transport Handled as non-hazardous material. Creation of a logistics system network, ensuring safety and performed completely within the company. No logistics system. Responsibility for handling is unclear.
Intermediate processing and approval Approval acquired for intermediate processing. Even for subcontracted collection and processing, the flow until recycling is clarified. Approval can be obtained from the government by making total system proposals. Not acquired. Expanded polystyrene is handled as a valuable resource, so business is expanded without
approval for intermediate processing. So for subcontracted collection and processing, the recycling flow in a manifest system cannot be clarified.

The volume of expanded polystyrene is reduced to as little as 1/100.

Approximately 98% of expanded polystyrene is air.

Approximately 98% of expanded polystyrene is air, relative to volume. Fish and packing boxes take up a great deal of space, so if they are collected unprocessed they are expensive to transport, even though the vast majority of what is being transported is air.

Expanded polystyrene compressed on-site.

Expanded polystyrene is compressed at the location where the waste is produced, either by fixed compressors installed at the workplace, or by mobile compressor vehicles. This enables expanded polystyrene to be compressed on-site to ratios of approximately 1/50 to 1/100. For example, expanded polystyrene that would previously have needed 10 trucks for transportation can be collected by only one truck in the Roadway System. This makes for a highly efficient transport system that helps reduce CO2 emissions and is considerate to the environment.
Approximately 10 truckloads can be collected in one truck.

Naturally, repeated use of CP solvent is possible.

The CP solvent used to dissolve the expanded polystyrene is separated from the polystyrene at the recycling plant. The separated CP solvent can then be used again to dissolve more polystyrene. The CP solvent depletes by only approximately 3 to 5% in each recycling process, so it can be reused repeatedly.

Current Processing Methods for Expanded Polystyrene and Main Problems

Roadway System Recycling Flow

An environmentally friendly system with zero emissions of smoke, odor and wastewater in all processes.

Recycling Plant

1)Processing capacity / 280kg/h (maximum monthly processing capacity approximately 140 t)
2)Solvent recovery ratio / 95% or more
3)Manufacturing capability for recycled polystyrene products /
Approximately 70 t per month
4)Machine size / Width 8.3 m _ Depth 8m _ Height 6.8m
Machine floor space: approximately 66.12m2

Recycling plant performance

In this plant it is possible to process 280 kg (gel) in one hour – approximately 140 kg net expanded polystyrene. The equipment at the plant was assembled at approximately a third of the cost of other big plant manufacturers, enabling processing costs to be lowered. In addition, the automatic centralized control system reduces the number of operators by two, and by being a system that conserves energy greatly contributes to the reduction of maintenance costs involved in plant operation. And since the solvent recovery ratio is 95% or more, only a small amount of replenishment is required. The gel viscosity is not specified and can be processed. Unlike at other big plant manufacturers it is easy to process. There is also a processing system for waste contamination in order to resolve problems at the plant itself, enabling the production of high quality recycled polystyrene. No smoke, odors or wastewater is emitted from the plant.

Location of recycling plants

■Ibaraki Plant I Moriya City, Ibaraki Prefecture
■Mie Plant I Iga City, Mie Prefecture (Established 2002)
■Saitama Plant I Yorii Town, Saitama Prefecture (Completion: September 2005)

Properties of recycled goods (recycled polystyrene resin)

There is almost no deterioration in the molecules of the recycled products, and the deterioration in the solvent is also extremely low at 1,500 to 3,000 ppm. This compares with other systems and heat compression that require the addition of virgin raw materials or are limited to producing recycled ingots. Consequently, ours is a complete recycling system that produces 100% recycled products.

Issue of reuse certificates

During plant development, we entered a partnership with a plastic manufacturer and signed a contract to trade all of the recycled polystyrene produced at our plants.
The recycling plant receives the gel after it has been processed, and after it is recycled we issue a reuse certificate for the company from which the waste was collected. From this it is possible for a company to know how, where, and in what amount its waste is recycled.

Recycled products

Recycling Flow

We support Environmentally Friendly Companis and the Local Community

We offer a complete system based on on-site processing

(End user business: general companies, food processing plants, home appliance retailers, etc.)

It is usual for waste produced by companies to be collected by special industrial waste treatment businesses. However, the number of companies that realize the importance of managing waste from the perspective of acquiring environmental ISO and achieving zero emissions has greatly increased. There is a strong trend towards processing as much waste as possible on-site.
•Support for achieving zero emissions in the company environment
•Creation of appropriate environmental standards for acquiring IS014001
•Creation of a good company image among consumers and local society
■Provision of very safe and high quality recycling processing through non-polluting processing
•Creation of efficient resources through reduced space and reduced costs
•Clarification of recycling flow and maintenance of reliability through reuse certificates
■Creation of highly reliable follow-up system though a tie-up with affiliates

The volume of expanded polystyrene is reduced to as little as 1/100.

Recycling plant construction

(Local administrations, municipalities, etc.)
Currently, it is a concern that the construction of regional processing plants could provoke opposition from local residents who fear damage to their environment, or that the construction could cause financial pressures on local authorities. The concept has advanced that waste that can be recycled into a resource should be done so properly. As such, the construction of a low-cost joint or
independent recycling facility has become necessary in order to improve the image of waste reprocessing with local residents. Roadway offers an environmentally friendly recycling plant that supports the living environment of the local community.
■Promotion of equipment cost reduction and reuse of local community resources by providing a recycling plant
•Supporting the living environment of local residents through the high quality recycling of waste
■Planning recycling plants to meet the needs of the local community

Roadway System Affiliate Structure

Creating links with affiliates to construct an economic system that is more considerate of people and the Earth.

Logistics System

The reduction of logistics costs is another important point to consider when constructing this recycling system. We use mobile compressor vehicles via our alliance with Shin MayWa Industries Ltd., to pick up processed gel from each area. Our company group has constructed a logistics system that covers the whole of Japan. We offer a true recycling service through a total logistics system that does not place cost burdens on customers. We provide a total system that is completely different from the systems of other companies. We trade gel in a responsible way and provide solvent deliveries in order to meet customer needs.

Mobile Compressor Vehicles and Compressor Equipment Line-Up

Solvent volume reduction and heat reduction

(When processing at the discharge site)

Comparison of method Solvent reduction heat reduction
1 Storage space small large
2 Logistics efficiency ※① 1 10
3 Energy use (electricity) 1.31KW/kg 3.67KW/kg
4 Energy use (kerosene) 0,26kg/kg
5 CO2 generation 0,66kg/kg 1.22kg/kg
6 Odor generation Few Many
7 Availability All Limited ※②
8 Preprocessing Easy Necessary ※③
9 Noise and vibration None Exist ※④
10 Environmentally Friendly Unfriendly
11 Safety
12 Recycled pellet quality
(average molecular weight)※⑤
240,000 180,000
13 Reproduction pellet sales price ※⑥ 100 65
14 Recycling application good inferior

①Comparison of case where solvent volatility is 1
②in the case of heat reduction, construction materials can not be available.
Also, colored polystyrene may not available
③necessary to remove the tape seal and clean the dirt
④There are noise and vibration, adverse effects on the human body and the environment such as odor generation
⑤molecular weight of virgin pellet is 300,000
⑥Comparison of case where solvent volatility is 100(2007survey)