PUR foam rebonding – how adhesive selection impacts polyol recovery
What is rebonding and why is it gaining importance?
Rebonding is a polyurethane foam (PUR) recycling process that enables the recovery of a valuable chemical component – polyol – without relying on petroleum-based raw materials. This method is becoming increasingly relevant as the furniture and upholstery industries move toward circular economy principles and reducing their environmental footprint.
The rebonding process uses PUR foam waste sourced primarily from old furniture or mattresses. Non-recyclable materials in such processes as wood, textiles, and upholstery fiber are removed, leaving only foam remnants with traces of adhesive from previous bonding processes. These foam scraps are placed in specially designed tanks, where a chemical process – developed enables the extraction of usable polyol.
How is PUR foam produced and what role does polyol play?
Thanks to rebonding, a portion of the necessary polyol can now be recovered from used foam waste, reducing dependence on virgin petroleum-based resources and improving overall material efficiency.
How different adhesives affect PUR foam recyclability
In upholstered furniture manufacturing, a range of adhesives is used – each with a different impact on the foam’s potential to be recycled via rebonding:
1. Solvent-based adhesives
These are older adhesive types that contain volatile solvents – either flammable or non-flammable – which pose health and safety risks to workers. While their use is being phased out for regulatory and safety reasons, solvent-based adhesives generally do not interfere with the chemical processes needed for polyol recovery.
2. Water-based adhesives (dispersion adhesives)
Often considered more environmentally friendly, some water-based adhesives still pose health risks, including respiratory issues such as asthma. More importantly, certain types contain polymers that block the chemical recovery of polyol from foam waste. Because it is extremely difficult – or even impossible – to physically remove these adhesive residues from the foam, such foam waste is often unsuitable for rebonding.
3. Hot melt adhesives (thermoplastic adhesives)
These adhesives are currently the best option for circular production. They are safe for workers and do not interfere with the chemical recovery of polyol from PUR foam. Their use supports both high-performance bonding and long-term recyclability.
Why choosing the right adhesive matters
From the perspective of sustainable upholstered furniture manufacturing, PUR foam rebonding represents a key strategy to reduce reliance on non-renewable resources. However, the success of this process depends heavily on the materials used upstream – especially the type of adhesive. By selecting hot melt adhesives, manufacturers can meet modern ecological standards while actively contributing to a circular economy in the furniture industry.
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