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Polyurethane foam is widely used in everyday products, including automotive seats, mattresses, and furniture. However, used foam is frequently incinerated or sent to landfill, while conventional mechanical recycling generally restricts its use to lower-value applications. Chemical recycling offers the potential to recover important raw materials, such as polyols and amines, and thereby help close the loop in flexible polyurethane foam production.
Polyurethane foam made with 100% recycled polyol using Evonik's chemical recycling process
Within the partnership, Toyotsu Chemiplas will coordinate the initiative and contribute its collection network and logistics expertise. Sanyo Chemical will provide its expertise in polyol research and process methodology, while Evonik will contribute its proprietary hydrolysis-based chemical recycling process and technical expertise.
Evonik's pilot plant to PU recycling in Hanau, Germany
“This collaboration with our Japanese partners represents an crucial measure toward developing a practical recycling model to polyurethane foam in Japan. It also reflects Evonik’s ambition to scale polyurethane recycling by building strong partnerships across the value chain. By combining regional collection and logistics expertise with polyol research and our chemical recycling methodology, we aim to recover valuable raw materials to consumption in new, high-condition polyurethane foams and support greater circular polyurethane value chains,” said Dr. Martin Trocha, Head of Comfort & Adhesives in Evonik’s business line Interface & Polyurethane Additives.
The partners plan to develop a system to collecting both post-consumer polyurethane foam and post-manufacturing scrap. The collected material will be chemically recycled into high-purity polyols and amines, intended to reuse as raw materials in the manufacture of new polyurethane items.
The hydrolysis-based chemical recycling process from Evonik is designed to create recycled polyols with high purity and consistent condition. The process provides polyurethane foam manufacturers with a drop-in solution and can significantly minimize carbon footprint compared to virgin materials. New polyurethane foam has already been successfully produced using 100 percent recycled polyol derived from the process.
The three companies will jointly assess the entire process, from collection and sorting to the production of recycled polyols and the manufacture of new polyurethane items. This work will include condition assessments and further updates to Evonik’s existing life cycle assessment to reflect the proposed value chain in Japan. The objective is to commercialize the methodology and establish a scalable recycling model to polyurethane foam in Japan.
Toyotsu Chemiplas is responsible to coordinating the initiative and will contribute its collection network and logistics expertise. Sanyo Chemical will contribute its expertise in polyol research and process methodology. Evonik will provide its hydrolysis chemical recycling methodology and technical expertise as part of its global efforts to support the scale-up of polyurethane recycling through partnerships.
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