Tech Talk: How we recycle 100% of foam waste
23.03.2026
At Appletree Surfboards, sustainability is not a side project. It is integrated into how we build boards every day. In this Tech Talk, Wieger explains how we recycle 100% of our foam waste.
During the shaping process, our CNC machines cut high-precision boards from solid foam blocks. The outer edges that are removed during shaping are not simply discarded, we reuse them in our packaging. This allows us not only to repurpose leftover material, but also to let customers physically see and feel the waterproof core material their board is made from.
Even with this reuse system, shaping inevitably creates additional leftover material and fine foam dust.
That is why we built a system to collect all of it and send it back for recycling.
From CNC dust to new foam
All foam scraps and dust are collected through an extraction system connected directly to our CNC machines. The fine, snow-like particles are stored in large bags and processed using an industrial compactor.
The compactor shreds and compresses the foam at approximately a 20:1 ratio, transforming light, voluminous waste into dense blocks that are efficient to transport.
Once enough material is collected (typically a full truckload) our foam supplier collects it from our factory here in Portugal.
When we finally had the volume
We wanted to implement this system years ago. The challenge was scale. This type of recycling only works when there is enough material to justify transport and processing.
After expanding our factory space, we are now able to collect sufficient foam waste to make this recycling loop viable.
This is an important step in reducing our environmental footprint while maintaining the highest construction standards.
For us, durability and sustainability are not marketing terms, they are long term commitments built into the way we design, build, and improve our boards.
If you’d like to see more of how our boards are built, take a look inside our factory.
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