Here to stay: Mattress foam

As part of the PUReSmart research project (2019-2022), Covestro, together with partners, has successfully developed a chemical recycling process. It is now possible to convert the plastic polyurethane back into high-quality chemical building blocks after the end of its useful life. Polyurethane is used in many products such as mattresses, upholstered furniture, and car seats. Thanks to chemical recycling, these everyday objects get a second life after the end of their lifespan – a prime example of a sustainable circular economy.

The European Union has funded the PUReSmart project with six million euros over a period of four years. The reason: Every year, approximately 40 million mattresses are disposed of in the EU. Each mattress contains an average of 15 to 20 kilograms of foam – an enormous potential for chemical recycling.

Every mattress holds recycling potential

At Covestro's pilot plant in Leverkusen, scientists have efficiently broken down old mattresses into their primary components – polyol and toluene diisocyanate (TDI). A new, high-quality foam is produced from the fully recycled raw materials. And all this without using polyol based on fossil resources. Under the name Evocycle® CQ Mattress, Covestro aims to close the loop in the PU mattress industry together with partners. This reduces the use of fossil raw materials and significantly lowers CO2 emissions.

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