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Successfully produced foam using recycled polyol

As a contributor to the URBANREC project “Mattress demonstrator”, Eurospuma (PT) is responsible for the formulation and production of a viscoelastic foam made with recycled polyol provided by RAMPF (DE). This foam is designed for a mattress top layer. DELAX and Aimplas will then build a mattress sample using this top layer with a new adhesive, developed by Rescoll.


At the beginning of November, Eurospuma announced a successful industrial trial of this brand-new viscoelastic foam made with recycled polyol. 


Eurospuma’s foam production process started by testing the recycled polyol. The purpose was to check how this raw material would change the foam. From this testing, Eurospuma got the following general results:


1.    Colour: the foam came out with a cream shade due to the dark-brown colour of the recycled polyol.


2.    Air flow: the foam became less air permeable. This factor is important for a mattress foam, henceforth Eurospuma improved the air permeability.


3.    Hardness: the hardness of the foam increased because of the recycled polyol particles.  


During the next steps, Eurospuma chose a polyol that is recycled from different end products with the best performance in their base-formulation. It helped polyol suppliers identify the best source of bulky waste and the right conditions to prepare it for industrial production.


Before setting up the industrial trial, the company tweaked the viscoelastic foam formulation to achieve the foam’s expected KPIs and therefore meet the expectations of the bedding industry. 


The final product met all the requested quality parameters. These include but are not limited to:


- Good breathability; 


- Soft-touch;


- 12% of recycled polyol content; 


- 50 kg/m3 density; 


- 1.50 kPa hardness.


The foam produced was sent for OEKO-Tex certification. Nevertheless, Eurospuma has successfully handed this development to other partners for project completion.

» Author: URBANREC NEWSLETTER

» Publication Date: 19/12/2018

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This project has received funding from the European Union’s Horizon 2020 research and innovation program under grant agreement N° 690103