Shipping Packaging — Foam (EPS/EPP)

Material Composition Assumptions

The default reference product is 1 kg of molded expanded polystyrene (EPS) packaging, composed of:

• Polystyrene resin: Expandable polystyrene beads produced from styrene monomer (derived from ethylbenzene, a petrochemical). Approximately 95-98% of the final product mass.
• Pentane blowing agent: N-pentane or isopentane, approximately 4-7% by weight of pre-expanded beads. Pentane is a volatile organic compound (VOC) that contributes to ground-level ozone formation. Most pentane is released during pre-expansion and molding.
• Additives: Flame retardant (hexabromocyclododecane, HBCD, or polymeric alternatives), anti-static agents, and colorants. Less than 1% by weight.

EPS packaging is approximately 95-98% air by volume. Typical density for packaging-grade EPS is 15-30 kg/m3. The extreme lightness means that per-kg emissions are relatively high, but per-unit-volume emissions are very low — which is why EPS remains widely used for protective packaging despite environmental concerns.

Expanded polypropylene (EPP) is an alternative foam packaging material with similar properties but different chemistry. EPP has slightly lower cradle-to-gate emissions (~3.0-3.2 kgCO2e/kg) and is more readily recyclable than EPS.

Manufacturing Geography

EPS production is moderately globalized, with conversion (molding) typically regional:

• Resin production: Major styrene/PS producers include INEOS, BASF, SABIC, and Chinese producers. Styrene monomer production is concentrated in petrochemical hubs (US Gulf Coast, Rotterdam, Middle East, China).
• EPS conversion: Bead expansion and molding is done regionally due to the high volume-to-weight ratio of expanded foam. Major converting regions include China, USA, Germany, Poland, and Japan.
• Grid intensity (China): 565 gCO2e/kWh (IEA 2024). Used as conservative default for the global supply chain.
• Grid intensity (USA): 390 gCO2e/kWh (IEA 2024).
• Rationale: The molding step requires significant steam for bead expansion and mold injection. Electricity is used for pre-expanders, block molds, and shape-cutting equipment. The upstream petrochemical chain (Scope 3) is the dominant emissions driver.

Regional Variation

Manufacturing Region	Grid Intensity	Estimated Score (per kg)	Adjustment vs Default
China (default)	~565 gCO2e/kWh	3.5 kgCO2e	Baseline
USA	~390 gCO2e/kWh	3.2 kgCO2e	-9%
EU average	~300 gCO2e/kWh	3.0 kgCO2e	-14%
Germany	~350 gCO2e/kWh	3.1 kgCO2e	-11%
Japan	~460 gCO2e/kWh	3.3 kgCO2e	-6%

Note: Because Scope 3 (upstream petrochemical production) dominates at 71% of total emissions, grid intensity variation has a proportionally smaller effect on the total score.

Provenance Override Guidance

A supplier or manufacturer may override the default CCI score by submitting:

1. Environmental Product Declaration (EPD) per ISO 14025 for the specific EPS or EPP product.
2. Resin supplier data: Specific PS/EPS resin cradle-to-gate PCF data from the resin producer.
3. Recycled content: Post-consumer recycled polystyrene (rPS) content can reduce upstream emissions. rPS availability is limited (~10% global recycling rate for EPS) but growing.
4. Factory energy data: Steam source (natural gas vs. coal vs. electric boiler), renewable electricity procurement.
5. EPP alternative: Expanded polypropylene (EPP) data may show marginally lower emissions due to different monomer production chemistry.

Methodology Notes

• CCI score of 3.5 kgCO2e/kg represents a conservative estimate for molded EPS packaging produced with Chinese grid electricity. PlasticsEurope reports 3.3-3.8 kgCO2e/kg for EPS granulate; the CCI score includes conversion energy for molding.
• Scope breakdown: Scope 3 dominates at 71% (2.5 kgCO2e/kg), driven almost entirely by styrene monomer and polystyrene resin production. Scope 2 is 20% (0.7 kgCO2e/kg) from molding and cutting electricity. Scope 1 is 9% (0.3 kgCO2e/kg) from steam generation and pentane emissions.
• Functional unit: 1 kg of molded EPS packaging, cradle to gate.
• Per-piece context: A typical EPS corner protector for a TV or appliance weighs 50-150 g, contributing approximately 0.2-0.5 kgCO2e per piece. A complete set of EPS cushioning for one appliance might weigh 0.5-1.0 kg total.
• End-of-life: EPS has very low recycling rates (~10% globally) and persists in the environment. End-of-life impacts are excluded from the cradle-to-gate score.
• Data gaps: Limited differentiation between EPS grades (packaging vs. insulation vs. food service). Insulation-grade EPS with graphite additives (e.g., BASF Neopor) has marginally different emissions per kg.