Dutch breakthrough in polyurethane foam recycling

Researchers at the University of Twente in the Netherlands have developed a new method to recycle polyurethane (PUR) foam. The breakthrough avoids toxic chemicals and offers a circular solution for millions of tonnes of foam waste worldwide.

PUR foam, widely used in mattresses, insulation and footwear, is difficult to recycle. Until now, recovery often required phosgene, a highly toxic gas.

Safer and commercial

‘For a long time, phosgene was the only way to break apart this foam,’ says project leader Professor Jurriaan Huskens. ‘That is simply unacceptable if you really want large-scale recycling.’

He notes the global market for PU is likely to grow from 24 million tonnes in 2020 to 31 million tonnes by 2030, underlining the importance of finding a recycling solution.

The TU Twente team found a safer compound called dialkyl carbonate, which breaks the polymer chains through carbonyl exchange. The process takes place in an autoclave at 210 °C over four hours, producing no harmful emissions.

Circular potential

‘We show that you can recover both the soft and hard parts of the foam,’ explains researcher Jean-Paul Lange. ‘This makes it possible for the first time to make PUR truly circular.’

The method achieves recovery of up to 70% of aromatic monomer and 80% of polyol, two key building blocks. These materials can be reused to create new, high-quality foam products for mattresses, sports insoles and medical applications.

Industrial scale-up

Researcher Ege Hosgor highlights the method’s real-world readiness. ‘We did not use artificially pure foam in the lab but actual products,’ he says. The team is now exploring industrial partnerships, including hospitals, to handle foam waste from medical applications.

Huskens believes the development offers ‘a real step towards a safe, circular future for plastics.’