Closing the materials cycle for mattresses

To promote more sustainable practices, the mattress industry has set up initiatives such as the US-based Mattress Recycling Council (MRC) and the German network ReNewTex. One of the latest examples is the Mattress Alliance, which was launched in Austria in 2024 and is committed to environmentally friendly and economically sustainable business models in the mattress industry. These organisations aim to help shape the market conditions and remove any obstacles to help smooth continued progress towards a circular economy.

Polyurethane (PU), the main constituent of mattress foams, is not easy to recycle because of its strong chemical bonds. The latest processes convert waste PU into polymer granules, which can be used to create new products, from soles for trainers to covers for mobile phones. Until now, however, it has only been possible to incorporate recycled materials into the production of new mattresses in limited circumstances. Greater material efficiency therefore remains a key objective when it comes to establishing sustainable product cycles.

The industry aims to use new chemical processes to break down used mattress foam directly into its main components so that it can be fed back in to the product cycle as a raw material. The long-term goal is to use both mechanical and chemical technologies to recycle PU foams as efficiently as possible once they have been carefully sorted by type in cutting plants. An alternative approach is to stop using PU in mattresses altogether. Manufacturers like Antecon from Italy already offer individual models with pocket spring cores and a reinforced edge that don’t contain PU and are 100 per cent recyclable.

To recycle mattresses efficiently, the source materials must be pre-sorted and clean, so manufacturers are increasingly being called upon to assume more responsibility. Countries including France, Belgium and the Netherlands as well as some US states have already introduced extended producer responsibility (EPR) systems to regulate the collection, disassembly and recycling of product components. The forthcoming revision of the EU’s Waste Framework Directive also plans to introduce an EPR system for mattresses that are largely composed of textiles.

Further important criteria for recyclable mattresses include circular components and Digital Product Passports. As one of Europe’s largest mattress manufacturers, the Aquinos Group is developing a digital tool for its own Schlaraffia brand to help fulfil these requirements. At this year’s imm cologne, Aquinos announced that it was introducing a chip into its mattresses that would contain information about all the components and materials used. The individual parts that make up mattresses are also becoming increasingly sustainable. Manufacturers like the pocket spring core specialist AGRO now offer a completely circular product portfolio comprising elements that have already been recycled. Innovations such as the water-based 365 Debonding Adhesive developed by SIMALFA make it easy to separate the mattress layers. The product was a category winner at the interzum forum italy award 2024.

The upcoming interzum in Cologne will bring together companies and experts who are working on the further development of circular solutions with the aim of closing product loops in the mattress industry and converting even more waste into valuable resources. As at previous editions, the international exhibitors’ stands will showcase a wealth of innovations. In addition, the Textile & Machinery Trend Forum will focus on the EU’s Digital Product Passport and provide industry-relevant information about its implementation – more important steps on the road to a circular economy.