#Recycling / Circular Economy

2021-11-18

Evonik partners with The Vita Group for pioneering efficient polyurethane mattress recycling process

Evonik has used its expertise in polyurethane (PU) chemistry to develop an efficient chemical recycling process for converting flexible PU foams back to the original polyol raw material. Evonik’s new hydrolysis recycling process has the potential to achieve circularity in the flexible PU foam industry.

The process helps the flexible polyurethane foam industry to increase circularity

Hydrolysis technology enables used flexible polyurethane foams and mattress materials to be recycled

Innovation will significantly reduce the number of mattresses incinerated or going into landfill each year

As the next phase of the development, Evonik will scale-up trials of its new process, which has been further strengthened by its partnership with The Vita Group, a leading provider of value-added and differentiated flexible PU foam products. The Vita Group has trialled the recycled polyols from Evonik's hydrolysis process in several of its flexible foam applications.

According to the latest report from EUROPUR (European association of flexible polyurethane foam blocks manufacturers), some 40 million mattresses are discarded each year in Europe alone, with the majority ending up as landfill creating the equivalent of 600 kilotons of waste: including more than?300 kilotons of PU foam. With the potential to recycle the main component materials used in flexible PU foams and PU foam-based mattresses, Evonik’s process offers significantly higher use levels of the recycled polyol compared with existing commercialized technologies.

Evonik’s solution will contribute to the global flexible PU industry’s sustainability expectations of reducing waste and increasing the use of renewable raw materials in the production of its products. This enables Evonik to expand its position as a leading solutions provider for the PU industry and supports the entire Evonik Group’s objectives of establishing a fully functioning circular economy.

“It’s only by recycling products back to their raw materials and reusing them over and over again that we will enable a fully circular economy,” said Ralph Marquardt, Head of Evonik’s polyurethane additives business. “Our new hydrolysis process delivers recyclates of a quality and performance similar to that of virgin raw materials. Thus, innovative foam producers like our partner The Vita Group can meet their own sustainability targets, while continuing to deliver high-quality PU products.”

“The Vita Group is renowned for our long-history of innovation in sustainability and investing in circular economy products. We recycle and rebond over 30,000 tons of trim each year, as part of our dynamic sustainability agenda,” said Ian W. Robb, Group CEO for The Vita Group. “Sustainability and innovation are central principles of every aspect of our business. We see it as our responsibility to be at the vanguard of the development of eco-friendly technology within our industry. This hugely exciting partnership represents a key milestone on our journey to achieving the circular economy we are all striving for, and we look forward to working closely together with Evonik.”

Evonik will showcase its latest polyurethane solutions, including its new hydrolysis recycling process at stand #E15, during this year’s UTECH Europe in Maastricht, Netherlands from 16-18 November.

“Production is a product”

From technical textiles and AI-driven robotics to the limitations of textile circularity: Professor Dr Thomas Gries looks back on more than two decades of development at ITA Aachen. In the interview, he explains why production technology remains a decisive success factor, discusses international collaborations and innovation ecosystems, and shares his views on the transformation of production landscapes and the challenges facing an increasingly regulated industry.

“We need to move away from the price trap and return to a value-driven mindset.”

With its new Textile Innovation Center, KARL MAYER is sending a strong signal for innovation, collaboration, and the future of textile applications. In this interview, Karl Josef Mayer discusses new opportunities in warp knitting, the processing of staple fibres, recycling, the changing role of machinery manufacturers, and why the textile industry must once again focus more strongly on the value of textiles. by Oliver Schmidt

“Innovation, resilience and international experience remain the great strengths of the Swiss textile machinery industry”

Geopolitical uncertainty, growing competitive pressure from China, new free trade agreements and the shift towards a circular economy are currently reshaping the global textile industry. In this interview, Cornelia Buchwalder discusses the current mood within the Swiss textile machinery sector, the industry’s distinctive innovative strength, new market opportunities in India and Asia, and the technological trends that could shape the upcoming trade fair cycle leading up to ITMA 2027.

Reju expands textile-to-textile recycling network with six international fabric manufacturers

Reju, a textile-to-textile regeneration company, is expanding its industrial network through collaborations with six fabric manufacturers in Europe and the Americas. The initiative aims to accelerate the integration of regenerated polyester into textile manufacturing and support the development of finished fabrics for commercial applications.

Trützschler expands technical service capabilities for spinning mills in Pakistan

Faster support, shorter downtime and advanced repair capabilities: customers across Pakistan can now benefit from the Trützschler Service Station at its new location in Lahore. By combining Trützschler service expertise with state-of-the-art diagnostic equipment, the new facility helps spinning mills resolve technical issues more quickly and maintain reliable production.

Stäubli to introduce new S3292 dobby for high-speed weaving at ITME India 2026

Stäubli will introduce its new S3292 dobby at ITME India 2026, taking place from December 4 to 9 at the India Expo Centre & Mart in Greater Noida, Uttar Pradesh. Designed for high-speed air-jet weaving, the new machine will be among the highlights of the company's presentation, which also includes warp preparation systems, cam motions, Jacquard technologies and digital services.

DITF develops bio-based binding fibers for wood-fiber insulation materials

As part of the CelluWoodFlex project, the German Institutes of Textile- and Fiber-Research in Denkendorf (DITF) are developing bio-based cellulose ester fibers as alternative binding fibers for flexible wood fiber insulation materials. In addition to the spinning process and the production of suitable staple fibers, the institute is also investigating how wood and cellulose fibers can be separated and recycled at the end of their useful life.

Magnera highlights HighPleat™ filtration media technology at FiltXPO 2026

At FiltXPO 2026, held on October 28–29 at the Minneapolis Convention Center in Minneapolis, Minnesota, Magnera highlighted advances in air filtration media architecture, with a particular focus on its HighPleat™ platform for MERV 8–10 applications. The technology combines a lofted fiber structure with optimized pore architecture to address the challenge of balancing filtration efficiency, airflow resistance and contaminant-holding capacity.

Ahlstrom expands depth filtration media production capacity at US facility

Ahlstrom has completed a major investment in its Kingston manufacturing facility in New York, USA, expanding production capacity for high-performance depth filtration media. The modernization of Line 3 is designed to improve manufacturing efficiency, enhance quality control and increase flexibility in producing different product widths.