The waste from rigid PU foam presents significant economic and logistical challenges for companies, making its effective management essential. During our project, we aimed to solve this problem, and thanks to our efforts, we are now able to introduce a new recycling method.
Until now, disposing of discarded or industrially produced rigid polyurethane boards has always been harmful to the environment, whether through burial or incineration. Today, we have developed a far more satisfactory method for the industrial-scale recycling of withdrawn PU foam.
Thanks to purman®’s innovation, which utilizes a patent-pending technology incorporating natural materials for rebonding, not only can the unwanted rigid PU foam be processed, but it can also be reused. This method is eco-compliant, green building compatible, and environmentally advantageous. As a result, the operations of many industries can become more efficient and environmentally friendly.
In the EMEA region, a significant amount of PU rigid foam, reaching millions of tons, is produced annually. This PU foam is primarily used in the construction industry for insulation and sandwich panels, and also plays a crucial role in refrigerator manufacturing and the automotive sector.
Scrap and waste produced during the manufacturing process
Post-consumer waste, that is, waste generated at the point of use
End-of-Life waste, a waste source formed at the end of the product's lifecycle
The current state of technology recognizes two main solutions for recycling PU rigid foam waste: chemical recycling and mechanical recycling.
Use of acid media to break down polyurethane bonds.
Breakdown of PU bonds occurs with water vapor and akali metal hydroxide as a catalyst at high temperature (205°C-340°C) under high pressures.
Trans esterification reaction by reacting PU foam with various diol compounds at elevated temperatures, preferably above 200°C.
Use of hydroxyl and amino-derived compounds to breakdown PU bonds.
When considering these methods of chemical recycling, they share a common characteristic: they are continuously evolving, but all of them are highly capital and energy-intensive processes, requiring further developments and research to improve their economic viability.
By adding various adhesives and bonding materials, properly prepared PU foam can be effectively bonded again.
This solution is primarily applicable to thermoplastic materials.
It's a extremely simple and cost-effective method; however, its applicability is limited.
Injection molding technology is also widespread for thermoplastic rigid PU materials.
In our purman® R&D project, we essentially focus on bio-based rebonding within the scope of mechanical recycling, and we are developing solutions for this method.
Our goal is to continuously innovate and experiment to create new hybrid PU materials with unique properties that can be used in various aspects of life while significantly reducing the waste stream of rigid PU foams.
To further enhance our environmental impact, we have developed a patent-pending method that allows for the rebonding of rigid PU foams with much less petrochemical content. In this process, we utilize natural materials, which ultimately reduces environmental strain in two significant ways: less material is wasted, as we recycle previously discarded materials, and we minimize the necessity for petrochemical substances in the rebonding process.
This innovative approach not only conserves resources but also aligns with our commitment to sustainable practices and reducing our ecological footprint.
In the coming decade, companies involved in PU foam manufacturing technology and waste management will face two crucial factors: The first and most significant change is that the End-of-Life (EoL) waste quantity of PU rigid foam products will exponentially increase in the market, necessitating the annual management of millions of tons of foam waste. Currently, this field is at the research and development stage in most regions.
The other significant change is that decision-makers worldwide will recognize that disposing of this valuable material in landfills or incinerating it, is not the most suitable solution. Therefore, regulations will not only become stricter but also incentivize companies to appropriately recycle such waste.
This is where the PURMAN pu foam recycling project comes into play!
The innovative green technology of purman® recycled rigid PU foam made its public debut with a win. Not just any win, but at the prestigious Red Bull Soapbox Race, returning to Budapest after 16 years. The Purma Team entered with a rolling Igloo and took first place.
Recycling PU foams is an important step towards environmental sustainability. While chemical recycling provides base materials for the production of new PU products, mechanical recycling can directly and cost-effectively produce marketable products.
As we delve into the realm of sustainable materials management, the recycling of rigid polyurethane (PU) foam presents both a significant challenge and opportunity. This post explores recent research trends, groundbreaking developments, and prospective recycling methods poised to shape the next decade.
