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Photo: Andritz/Recypur
02.09.2022

New mattresses made of industrial & post-consumer foam waste

  • Recypur successfully starts up a complete airlay line delivered by ANDRITZ for its mill in L’Alcúdia, Spain

The airlay line is designed for recycling of post-industrial and post-consumer foam and was developed specifically for the bedding and furniture industry, with material heights reaching 20 cm and densities of up to 120 kg/m3. Experimental tests carried out together with experts from ANDRITZ Laroche led to the conclusion that the mechanical method for recycling polyurethane is the most versatile and reliable.

With a capacity of 1.2 t/h, this airlay line enables Recypur to supply new mattresses made of industrial & post-consumer foam waste from old mattresses. This well proven process allows to reduce the environmental impact, increase self-sufficiency and eventually reduce the use of polyurethane. Such a set-up also allows multiple functional materials to be incorporated into the blend, such as flame-retardant, conductive and insulating fibers, among others. Thanks to this tailored approach, Recypur is now able to expand its diversification, innovation and reputation on the Spanish market.

  • Recypur successfully starts up a complete airlay line delivered by ANDRITZ for its mill in L’Alcúdia, Spain

The airlay line is designed for recycling of post-industrial and post-consumer foam and was developed specifically for the bedding and furniture industry, with material heights reaching 20 cm and densities of up to 120 kg/m3. Experimental tests carried out together with experts from ANDRITZ Laroche led to the conclusion that the mechanical method for recycling polyurethane is the most versatile and reliable.

With a capacity of 1.2 t/h, this airlay line enables Recypur to supply new mattresses made of industrial & post-consumer foam waste from old mattresses. This well proven process allows to reduce the environmental impact, increase self-sufficiency and eventually reduce the use of polyurethane. Such a set-up also allows multiple functional materials to be incorporated into the blend, such as flame-retardant, conductive and insulating fibers, among others. Thanks to this tailored approach, Recypur is now able to expand its diversification, innovation and reputation on the Spanish market.

The scope of supply includes a blending line with five feeders, an Exel 1500 for fine opening, an Airlay Flexiloft+ with 2.20 m working width, a recycling machine and an oven.

Airlay lines strongly support the circular economy and are part of ANDRITZ’s comprehensive product portfolio of sustainable solutions that help customers achieve their own sustainability goals in terms of climate and environmental protection.

Recypur, based in the Spanish province of Valencia, is part of DELAX, a Spanish group specialized in manufacturing and commercialization of innovative beds and mattresses. This company is the first Spanish manufacturer of recycled flexible polyurethane foam cores from post-consumer foam waste.

Source:

Andritz AG

(c) Indorama Ventures PCL
21.06.2022

Indorama Ventures works with Auping and TWE Group to deliver a fully circular mattress

The sustainable collaboration and innovation between Indorama Ventures (IVL), Auping and TWE Group presented a certified cradle to cradle process for mattress components across nonwoven applications, at Techtextil, Frankfurt, 21st to 24th June 2022.

Using circular research and design, the industry partnership between IVL Mullagh (Ireland), Auping and TWE Group has resulted in a perpetual, sustainable economic business model, for manufacturers globally. The inclusion of safe raw materials within mattress manufacturing allows the materials to be easily disassembled at the product’s end of use in order to be further reused as same components or recycled into new raw material at the same quality level, to enable versatile textile applications.

The sustainable collaboration and innovation between Indorama Ventures (IVL), Auping and TWE Group presented a certified cradle to cradle process for mattress components across nonwoven applications, at Techtextil, Frankfurt, 21st to 24th June 2022.

Using circular research and design, the industry partnership between IVL Mullagh (Ireland), Auping and TWE Group has resulted in a perpetual, sustainable economic business model, for manufacturers globally. The inclusion of safe raw materials within mattress manufacturing allows the materials to be easily disassembled at the product’s end of use in order to be further reused as same components or recycled into new raw material at the same quality level, to enable versatile textile applications.

Designed for disassembly to optimize the use of existing resources, reduce carbon footprint and support customer objectives all along their customers’ supply chain. This circular industry collaboration begins with design, where the mattress is constructed using only two different base materials, 100% PET polyester textiles and steel wire pocket springs connected with Niaga®️, a non toxic reversible adhesive, making the mattress easy to disassemble and recover.

IVL, Auping and TWE’s shared vision for a better world is demonstrated through their connected and innovative circularity that helps to close the loop. Auping collects, sorts and separates the collected fabrics, which then go to IVL Mullagh for processing, melting and extrusion to form polyester staple fiber. These staple fibers are then converted by TWE Group into nonwovens for use in Auping’s Evolve mattress, a fully circular mattress. Following the end of mattress use, the material recovery process simply starts again.

Auping estimates that annually more than 40 million mattresses are disposed of in Europe alone, the majority of which are incinerated. Their take back system in the Netherlands ensures that when their new mattress is delivered, the old mattress is retrieved and recycled, irrespective of the brand, ensuring existing materials are continually optimized, diverted from landfill and kept in use to achieve a circular economy.

Source:

Indorama Ventures PCL

14.05.2019

Devan launches two new sustainable technologies

Textile innovator Devan Chemicals will launch two new technologies at the upcoming Techtextil show in Frankfurt (May 14-17). Bio-flam, a bio-based flame retardant product and Odour Breakdown, a wash durable, non-biocidal odour control solution.
As tradition goes, every two years Devan participates in Techtextil, the leading international trade fair for technical textiles and nonwovens. In the quest for sustainability and transparency every company faces these days, the new Devan technologies offer answers to product developers and portfolio designers.

Textile innovator Devan Chemicals will launch two new technologies at the upcoming Techtextil show in Frankfurt (May 14-17). Bio-flam, a bio-based flame retardant product and Odour Breakdown, a wash durable, non-biocidal odour control solution.
As tradition goes, every two years Devan participates in Techtextil, the leading international trade fair for technical textiles and nonwovens. In the quest for sustainability and transparency every company faces these days, the new Devan technologies offer answers to product developers and portfolio designers.


Bio-flam
Some facts & figures: There are at least 5000 fire incidents each day in the EU. Yearly, about 70 000 people are hospitalised with fire-related injuries. Fires cause pollution. So sustainable fire performance of products is an economic, environmental and human necessity. Take the example of mattresses: tests indicate that when on fire, non-FR treated products give less than 5 minutes escape time. Unfortunately, that is not enough time for the fire brigade to arrive. Needless to say that to increase escape time, to reduce the risk and to save lives, products need to be flame retardant. The challenge is to obtain flame retardant properties in the most natural way, to find the right balance between safety for the people and for the planet.

Companies can do this by replacing raw materials from a non-renewable source, by bio-based FR treatments, which are made from renewable sources and do not contain halogens or heavy metals, as described in the norm EN 16785 1:2015. Bio-based FR treatments, like Bio-flam, are made from renewable, vegetable sources and enable the FR treated products to be biodegradable. The active components are 100% halogen- and heavy metal-free. A welcome innovation for the bedding industry, as the European Commission requires mattresses to be recyclable by 2030 in order to reduce landfill.

Bio-flam P307 is the first introduction in the new Devan BIO-FR family, and is biodegradable and is developed to be used on 100% cotton or cotton/viscose mixtures, in order to create an ecological concept, safe for people and planet, whatever might happen. Bio-flam P 307 is developed for mattress ticking to pass EN 597 1&2. The Devan researchers are developing other bio-based products for other market segments and for other fire standards.

More information:
Devan Chemicals NV Devan
Source:

Marketing Solutions NV