Recycling PUR is essential for reducing waste, conserving raw materials, and decreasing the environmental footprint of industrial processes.
April 15, 2025
Polyurethane (PUR) is a versatile material used in many diverse industries, including construction, automotive, and refrigeration. Its widespread use also creates significant environmental challenges, largely regarding waste disposal and end-of-life products. Recycling PUR is essential for reducing waste, conserving raw materials, and decreasing the environmental footprint of industrial processes. In response to growing environmental concerns, some regulations require that specific PUR-based products include a minimum percentage of recycled PUR.
To protect the environment, some countries, like France and the Netherlands, have made it mandatory to collect and recycle used mattresses. The automotive industry is also doing its part: modern cars contain about 15% polyurethane in the plastics used. The European Union has stipulated that at least 25% of plastic used in new cars must come from recycled materials; of this 25%, an additional 25% (6.25% of the total) must be obtained from reusing end-of-life components. In practice, this means that car manufacturers are required to recover and reuse a significant portion of plastic from scrapped cars to produce new vehicles.
This legal framework emphasizes the need for efficient and scalable recycling solutions.
Because polyurethane is a thermoset polymer, recycling poses some difficulties. Its complex chemical composition and diverse applications require specialized technologies that can recover and repurpose it effectively. Successful recycling must ensure that the recycled material’s properties match those of virgin PUR, allowing it to be reused for the same applications without compromising quality. Our team constantly researches methods to improve the efficiency of our equipment and plants, tackling these recycling challenges and passing on the benefits to our clients.
Mechanical recycling: transforming waste into a resource
One of the most effective methods for processing PUR waste, mechanical recycling, involves grinding the PUR into a fine powder. This is then repurposed as a solid filler and added into “fresh” polyol. When manufacturing continuous panels, for example, production scraps can be collected, ground, and reintroduced into the line for new panels.
To process recycled PUR as a solid filler, we developed a specific process, with dedicated equipment: a re-integration module for premixing the PUR powder with polyol, a dedicated dosing unit, and a mixing head.
These technologies ensure recycled PU is used easily and effectively, offering important environmental and cost benefits.
Innovations in rigid foam recycling
Our commitment to sustainability extends to recycling rigid polyurethane foams, opening new possibilities for reusing specialized materials. For example, insulation materials from end-of-life refrigerators can be processed to create high-performance Vacuum Insulation Panels (VIPs). That was the goal of our Life-VICORPAN project, developed with BASF and the EPTA Group: to explore reusing PUR waste, shredding it and compressing it to form new VIPs that were able to achieve lower thermal conductivity (lambda of 5.2 mW/m/K).
These VIPs not only outperform traditional foams in thermal efficiency but also set a new benchmark for recycled materials by delivering unmatched quality.
Chemical recycling: closing the loop
Chemical recycling takes polyurethane processing a step further by breaking it down to recover polyol. It significantly reduces the need for new raw materials, offering a more sustainable alternative that aligns with the circular economy’s objectives.
We have extensive experience in chemical storage, handling, mixing, and transferring for virtually every PUR application. This background allows us to partner with customers and raw material suppliers to provide customized industrial solutions for chemical recycling through in-house and straightforward usage of recovered polyol for production. The process gives manufacturers the ability to produce new PUR products that match the quality and functionality of those made with virgin materials.
Our expertise in polyurethane recycling showcases the technology’s transformative potential in advancing sustainability in the manufacturing sector. By developing innovative machinery and processes, we enable manufacturers to embrace recycling as an integral part of their operations.
