Twente scientists crack the code on foam recycling

Researchers at the University of Twente have developed a groundbreaking method for recycling polyurethane foam from mattresses, furniture, and household sponges, eliminating the need for toxic chemicals. This discovery offers a circular solution to the millions of tons of hard-to-recycle polyurethane waste that typically ends up in landfills or is incinerated. The researchers were able to completely disassemble the foam into its original building blocks, which can then be used to create new foam products, making polyurethane truly circular for the first time.

Polyurethane (PUR) foam, a common material used in mattresses, furniture, and numerous other products, often ends up in landfills or is incinerated because it is difficult to recycle or reuse. Traditional methods of recycling PUR have been limited, either recovering only parts of the foam or requiring highly toxic substances to break it down into its basic components. Jurriaan Huskens, the project leader of the study, noted that the historical reliance on phosgene, a highly toxic substance, to dismantle this foam is unacceptable for large-scale recycling.

A safer, greener solution

Twente researchers have developed a method to completely disassemble polyurethane foam into its original building blocks without using hazardous chemicals. This innovative process employs a relatively safe and environmentally friendly compound to efficiently break down the foam into usable raw materials. These raw materials can then be used as the foundation for creating new foam. According to Professor Jean-Paul Lange, this method enables the recovery of both the soft and hard parts of the foam, allowing for the achievement of true circularity for PUR.

The newly developed method is applicable to various types of foam found in mattresses, furniture, sports insoles, and medical applications. This broad applicability enhances the likelihood of the technology's rapid adoption by the industry. Ege Hosgor, the study's first author, emphasized the significance of this finding, noting that they used foam from real-world products rather than artificially pure foam in the lab.

Toward industrial-scale recycling

This new approach represents a significant stride toward a circular economy for plastics and will substantially reduce waste. The researchers are now focused on further developing and scaling up the method to enable recycling on an industrial scale. Huskens noted that this process is not only safer but also provides a real solution for the millions of tons of foam discarded worldwide.