Advancing Circular Solutions for Polyurethane Waste
Each year, more than 2 billion pounds of flexible polyurethane foam are used in the U.S., and over 86% ends up in landfills or incinerators. This creates environmental challenges—from greenhouse gas emissions to microplastic pollution—while valuable materials are lost. Existing recycling methods, like shredding or chemical breakdown, are costly, inefficient, and limited to low‑value applications. The need for scalable, high‑impact solutions has never been greater.
Research sponsored by the Mattress Recycling Council and a breakthrough grinding system developed by RoCo® can transform foam waste into fine powders. These powders are free‑flowing, about the size of a grain of sand, and can be tailored for different uses by adjusting particle size and surface chemistry.
This innovation creates new opportunities across industries. The powders can enhance coatings, plastics, adhesives, sealants, rigid foams, and cementitious materials. Early results show benefits such as lighter weight, improved insulation, and better noise reduction. Looking ahead, the technology could even support advanced fields like lightweight aerospace materials or biomedical applications.
Preliminary life cycle analysis shows the process has minimal environmental impact, with negligible emissions, water use, and energy consumption. By diverting foam waste from landfills and creating sustainable material streams, RoCo® is proving that circularity and profitability can go hand in hand.
Read our Executive Summary and Full Report.
Partner With Us
We invite collaboration with industry leaders, researchers, and innovators who share our vision for a circular future. If you’re interested in partnering with us, exploring applications for engineered powders, or learning more about our work, please contact us. Together, we can accelerate the transition toward sustainable materials and new market opportunities.
Our Thanks to MRC
We extend our sincere gratitude to the Mattress Recycling Council (MRC) for supporting this project and championing innovation in polyurethane recycling. Their commitment to identifying new markets for recycled foam has been instrumental in advancing this work and opening pathways to a more sustainable future.