Florida, US – Edge Global Innovation (EGI) has created a process that can turn waste polyurethane foam from old mattresses into polymer pellets. These can be used to make a wide variety of moulded products, such as shoe soles, phone cases and rubber gaskets. It can also be used to recycle industrial scrap foam.
The company developed a process and associated machinery to reduce the foam’s volume by 90%, without the use of solvents or catalysts. The result is a thin, flexible sheet that can be ground and mixed with additives to create reformable pellets comprising up to 75% recycled foam. The balance is made up of the additives, including colorants, plus virgin polymer, with the precise nature of the composition tailored for specific end uses.
EGI has formed a subsidiary, Vitricycle, to manufacture and market the pellets, and patents are pending in the US, the EU and China. The company is now looking to license its IP, and is seeking investors to help develop the technology and find new markets. The research was sponsored by the Mattress Recycling Council (MRC).
“We see tremendous potential,” said Vahid Serajian, Vitricycle’s CEO. “By converting bulky, hard-to-recycle mattress foam into versatile pellets, we’re not only addressing a major environmental challenge but also creating new opportunities for sustainable manufacturing across industries. Our goal is to lead the way in transforming waste into valuable resources and contribute to a more circular economy.”
There is also the potential for mattress recyclers to process the foam on site. This would allow them to make a high-value product to sell directly into secondary markets.
“This is an exciting new development that can open the door for making many high-value products from recycled polyurethane foam,” said Mike O’Donnell, chief operating officer of MRC. “We look forward to seeing commercial adoption of this technology to improve the circularity of mattress foam.”
