PUReSmart develops innovative solutions for breakthroughs in the recycling of polyurethane foam waste

Although the polyurethane industry is very concerned about waste recycling, just a few years ago, there was no good solution for the disposal of discarded mattresses, and about 60% ended up in landfills and the remaining 40% incineration. With the joint efforts of all parties, especially the solution proposed by PUReSmart in the European Union, it is revolutionizing the traditional integrated system of mattress production and recycling, significantly improving the recycling efficiency and recycling effect.

By combining intelligent mechanical recycling technology with chemical decomposition technology developed by PUReSmart, an innovative process for the chemical decomposition of waste polyurethane is close to becoming a reality and enables flexible polyurethane foam to be fully recycled. This technology is more conducive to driving carbon reduction in the polyurethane industry, thereby aligning the industry's development with its environmental goals.

Polyurethane foam is one of the most important plastic products in the world and can be used in a variety of applications, but waste recycling is a challenge for the polyurethane industry. In this context, the EU-funded Puresmart project brings together 9 partners from 6 countries to find new approaches and technological paths. The goal of the project is to recycle more than 90% of polyurethane waste and convert it into new and usable products. The Puresmart Project Alliance is developing smart sorting technology that separates polyurethane materials into unused raw materials and breaks them down into basic chemical components.

Four years ago, when the PUReSmart Alliance set out to find ways to transform the production-application-waste model of polyurethane into a circular economy model, the consortium came up with a practical idea from the beginning: polyurethane recycling should start with a solid mechanical separation process that facilitates subsequent chemical decomposition.

This line of thinking has proven to be effective. Redwave first proposed a solution that uses near-infrared sensors to detect and sort polyurethane waste in order to better repurpose flexible polyurethane foam. NIR reflectance spectroscopy has been used to detect and classify various thermoplastics such as PET and PE, and is now being used to sort polyurethane foam for the first time.

It is understood that Redwave's R&D team has developed reliable solutions for polyurethane waste sorting, including sorting all aspects of polyurethane flexible foam. Redwave's sorting equipment can identify and sort 20-30 different types of polyurethanes, such as MDI-based polyurethane foams, conventional polyurethane foams, high-resilience roll paper foams, and flexible polyurethane foams containing additives such as flame retardants.

At present, relevant companies are also upgrading the waste polyurethane material sorting system to be more conducive to the recovery of polyurethane's most important synthetic raw materials polyols and isocyanates in the downstream chemical decomposition process.

In recent months, Recticel Engineered Foams, a member company of the PUReSmart Alliance, has conducted various experiments to reproduce polyurethane foam by recovering polyols and isocyanates obtained from Covestro's pilot plant.

Thermoplastic Polyurethane (TPU) is a type of elastomer that is known for its flexibility, durability, and resistance to abrasion, oil, and chemicals. It is a versatile material that can be used in a wide range of applications, including footwear, automotive parts, industrial seals, medical devices, and consumer electronics.

TPU is created by combining a polyol and an isocyanate in a reaction that forms a polyurethane chain. The resulting material has a unique combination of properties, including high tensile strength, good elongation, and excellent tear resistance. It can be processed using various methods, such as injection molding, extrusion, and blow molding, allowing for the production of complex shapes and designs.