Invented to be reinvented

When Otto Bayer discovered PU in 1937, its future was uncertain. His superiors doubted its usefulness, while the test department dismissed it as suitable only for the creation of imitation Emmental cheese. Yet, as Louis Pasteur famously said, “Fortune favours the prepared mind.” Bayer recognised the material’s true potential, and over the decades, it has continuously evolved to meet our needs in unforeseen ways.

Few materials play such a vital role in our everyday lives as PU. From the food we eat to the buildings where we live and work to the cars we drive, PU is woven into the fabric of modern society, often in ways we don’t even realise.

Food often travels thousands of kilometres before it reaches our plates. PU is there along every step of the way, from insulating animal sheds and refrigerated containers to local storage in supermarkets and domestic refrigerators. It is estimated that in some countries up to 50% of food produced is wasted before it reaches consumers, mainly due to inadequate refrigeration along the supply chain. However, thanks to the incorporation of PU in refrigeration systems, today’s A++ models are 60% more efficient than similar refrigerators made just 15 years ago. 

In a similar vein, where do we spend most of our time? In the buildings where we live, work and learn. Yet, the energy required to heat and cool these buildings presents a significant challenge in our fight against climate change. At the same time, cars remain the primary mode of transport for many, despite their significant contribution to greenhouse gas emissions. The solution is not always simple: how can we reduce energy use while meeting the increasing demands caused by growing populations? Of course, as a lightweight, durable and highly efficient insulator, PU can greatly increase energy efficiency in both our buildings and vehicles. With a drastic increase in housing demands and a rise of electric vehicles, PU’s properties have never been more essential. 

Looking ahead, global energy demand is projected to double within the next 50 years. Meeting this demand will require a significant shift towards alternative energy sources. PU is essential in the production of modern composite materials for the large blades of wind turbines, improving their lifespan and efficiency. Furthermore, solar modules now feature foam frames and TPU foils, making for lightweight, durable in-roof installations, more sustainable than previous designs. 

Even as we explore the vast array of applications for PU, we barely scratch the surface of its remarkable potential. The true excitement lies in its ability to grow, adapt and innovate. New applications are emerging continuously. This material was invented to be re-invented, and as our needs change, so will PU. 
 

It is clear PU already does and has immense potential to contribute to a sustainable future in a multitude of ways. However, while its applications can make it a key driver of sustainability, its future ability to realise this potential will depend on the industry’s approach to circularity, regulatory support and collaboration across the value chain.

A truly sustainable PU industry requires a shift toward a circular life-cycle, where production, use and end-of-life management are integrated into a closed-loop system. Achieving this demands coordinated action across the value chain, ensuring innovation in materials, recycling and regulatory frameworks aligns with our long-term environmental goals.

A critical area for development is the transition away from fossil-based feedstocks. Innovations such as the mass balance approach enable the gradual integration of sustainable raw materials into existing production processes while maintaining product performance. Third-party certification ensures transparency, credibility and industry-wide adoption of these sustainable alternatives.

Particularly in this area we also see the importance of cross-sector and industry-wide collaboration in accelerating the development and deployment of sustainable PU solutions. Stronger partnerships among industry leaders, academic institutions and research institutes are necessary to drive innovation, while breakthrough technologies facing high uncertainty for market entry benefit greatly from shared industry facilities and cooperation.

Besides industry action, legislative frameworks are needed to facilitate sustainable innovation. Reducing regulatory and administrative burdens is essential. Simplifying permitting processes, ensuring planning reliability and streamlining legislation can accelerate market entry for sustainable solutions while allowing new technologies to operate long enough to generate reasonable returns on investment to fuel future research and development.

Although the environmental benefits of PU applications are apparent within the industry, their benefits are not always translated to public perception. Promoting the benefits of innovation in sustainable PU products and production, as well as standardised sustainability labelling and transparent life-cycle assessments, can build consumer confidence and boost the demand for such products.

PU represents a cornerstone of sustainable development across multiple industries, but its full potential will only be realised through decisive industry and policy action. By fostering an environment that supports circularity, encourages technological advancements and incentivises sustainable choices, the PU industry can solidify its position at the centre of the green transition.