MRC’s research drives smarter mattress recycling—boosting efficiency in collection and dismantling while creating new markets for reclaimed materials.

The focus of 45
completed projects:

Collection:

Improve mattress quality
and decrease
handling times

Transportation:

Reduce transportation
costs and
carbon impacts

Deconstruction:

Lean manufacturing,
fire safety
assessments,
automation

End Markets:

Innovative ways
to repurpose
mattress materials

Among the 45
research projects,
a variety of
interesting concepts
have been explored
to find new uses
for mattress foam
and textiles.

Some ideas
pushed the limits
of imagination
and technology
but have been
put on the shelf
because the
commercial market
is not there –
at least at the moment.

Instead,
this report will focus
on projects with
commercial potential.

Vitrimerization

MRC funded Vitricycle's research to transform mattress foam into
base polymers.

· A Houston pilot facility is now manufacturing vitrimerized polymers from post-consumer mattress foam.

· This process has the potential to be a
MAJOR end-of-life outlet for mattress foam.

Oleo Sponge

MRC funded research at Arizona State University to chemically modify mattress foam to be used for oil spill clean-ups.

· $2 billion potential global market

· ASU seeking development partners

· Patent pending

Powdered
Mattress Foam

Mechanically Ground Functionalized Foam

With MRC support, RoCo developed a process to produce mechanically ground functionalized foam.

· Polyurethane mattress foam is ground into a powder the size of a grain of sand.

· Testing underway in target applications.

· Possible applications include fillers in cement and rigid foam or as an additive in coatings, engineered plastics, adhesives, and sealants.

· The powders could also be used to make new mattress foam.

Life Cycle Analysis

Much can be saved with just one recycled mattress. Take a look:

· One recycled mattress saves 500 gallons of water.

· One mattress saves the amount of power needed to light a home for three days.

· Recycling one mattress reduces greenhouse gas emissions as if we drove 60 fewer miles.