Key Findings
Evonik, Toyotsu Chemiplas Corporation, and Sanyo Chemical Industries, Ltd. have launched a collaborative initiative to develop a scalable polyurethane (PU) foam recycling model in Japan. The partnership integrates collection networks, logistics, and chemical recycling technology to convert discarded foam into recycled polyols and amines. The ultimate objective is the commercialization of this recycling model within the Japanese market.
Technical Details
The initiative centers on Evonik’s proprietary hydrolysis-based chemical recycling process. Unlike mechanical recycling, which often results in lower-value applications, this chemical approach recovers raw materials with high purity and consistent quality. Key technical aspects include:
- Input Materials: The system targets both post-consumer polyurethane foam and post-industrial production scrap.
- Output: The process yields recycled polyols and amines that serve as “drop-in” solutions for PU manufacturers.
- Performance: Evonik has already successfully produced new polyurethane foam using 100 percent recycled polyol derived from this process.
The partners will jointly evaluate the entire value chain, including collection, sorting, and the manufacture of new products. This evaluation includes quality assessments and updates to Evonik’s existing life cycle assessment to reflect the specific Japanese value chain.
Background & Context
Polyurethane foam is ubiquitous in automotive seats, mattresses, and furniture, but is frequently incinerated or sent to landfills. To address this, the three companies have divided responsibilities based on core competencies: Toyotsu Chemiplas manages coordination, collection networks, and logistics; Sanyo Chemical provides expertise in process technology and polyol development; and Evonik contributes the hydrolysis technology and technical expertise.
Significance & Outlook
By recovering valuable raw materials, the initiative aims to close the loop in flexible polyurethane foam production and reduce the carbon footprint compared to virgin materials. This collaboration is part of Evonik’s broader strategy to scale PU recycling globally through value chain partnerships.
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