Research: Completed Reports
Using Recycled Mattress Textiles to Make Composite Products
Posted: October 2023
Category: New Markets
MRC funded a research project by Dr. Ram Gupta of Pittsburg State University, who successfully produced a soybean oil-based polyurethane composite that incorporates non-woven recycled mattress textiles – shoddy, cotton and coconut coir – that could be used to manufacture durable composite products suitable for construction, automotive and other applications. The end results were a low carbon footprint composite with excellent physical properties and versatile end uses.
2022 Mattress Age Study
Posted: July 2023
Category: Technical Documents
A new study was conducted to estimate the average time between mattress manufacture and consumer disposal. The average age for all units was 13.9 years. Foundations averaged 15.1 years. Innerspring and all-foam mattresses averaged 13.2 years. The results of this study do not necessarily represent the useful life of mattresses and foundations. Several factors besides durability can influence a consumer’s decision to discard a mattress.
The purpose of the study was to provide stakeholders with data to make informed decisions and develop effective strategies to improve recycling processes, reduce waste, and promote sustainability.
In 2019, MRC conducted a study in California, Connecticut and Rhode Island and determined that the average age of recycled mattresses was 11.2 years. However, that study found that 65 percent of the mattresses were not counted because the manufacturer’s tag was missing.
Cotton, Coir from Mattresses can be Composted
Posted: June 2023
Category: New Markets
About 1,300 tons of cotton fibers and coir (coconut fiber) are extracted from discarded mattresses annually, according to Mattress Recycling Council’s 2021 mattress composition study. Most of these materials are landfilled due to a lack of secondary markets. In 2022-23, MRC launched a study to understand if cotton and coir (combined together) could be composted in commercial composting facilities in California. GreenWaste Z-Best Composting Facility in Gilroy, Calif., concluded, through standardized processing and testing, that composting could be a viable solution for mattress recyclers seeking to divert this material from California landfills.
Mattress Textiles Can Be Used in New Batteries
Posted: April 2023
Category: New Markets
A successful three-year study has found that recycled mattress materials, specifically non-woven textiles, can be used for rechargeable energy storage devices such as supercapacitors and batteries. MRC funded the study by Dr. Ram Gupta at the National Institute for Materials Advancement at Pittsburg State University in Kansas. The research is significant due to the global shortage of carbon feedstocks for making electrodes, which are needed to satisfy the growing demand for rechargeable batteries. Recycled mattress materials may provide an inexpensive, clean, and abundant feedstock that can fill current and emerging needs. Being recycled materials, they also have a much lower carbon footprint relative to other feedstocks used today. The research team is interested in exploring commercialization potential through developing industry relationships.
Recycling Textiles with Enzymes Results Mixed
Posted: March 2023
Category: New Markets
MRC sponsored a research study with Rensselaer Polytechnic Institute to explore the technical feasibility of recycling shoddy using enzymatic catalysis in a two-step process to convert its components into building block chemicals. The RPI team was able to demonstrate that enzymatic digestion can be an effective way to recycle cotton-polyester blends with varying compositions. Unfortunately, yields in this study were rather low and further research will be necessary. MRC continues to explore other alternative solutions for recycling shoddy and other mixed mattress fibers.
Discarded mattresses commonly contain shoddy felt pads used as a barrier layer between springs and comfort foam. Shoddy is manufactured by compressing scrap natural and synthetic fibers into a dense pad containing mostly cotton and polyester fibers. This material is very difficult to recycle into other useful products and is typically landfilled.
LCA Study Finds Significantly Favorable Impact
Posted: November 2022
Category: Recycling Efficiency
MRC contracted with Scope 3 Consulting to conduct a Life Cycle Analysis (LCA) of our California operations. The purpose of the LCA was to describe and measure the environmental impacts and benefits to establish baseline environmental performance parameters for the program. The LCA analysis found significantly favorable environmental benefits in a number of key areas including the displacement of 75 million pounds of greenhouse gases in 2021. MRC’s expectation is to use the results of this study as a benchmark by which future technologies will be evaluated.
Mattress Recycling Equipment Guide Released
Posted: Updated April 2023
Category: Recycling Efficiency
Digest: The Mattress Recycling Council has assembled a list of vendors and machinery intended to assist mattress recycling operations. The list features vertical and horizontal balers, shredders, and foundation/box spring separators. This is a free resource that will be periodically updated with new vendors and equipment.
Foundation Wood Market Needs Further Study
Posted: January 2022
Category: New Markets
Published in January 2022, this white paper explores potential markets for foundation wood including particle board, medium density fiberboard, pellets, fire logs, pallets, animal bedding and oriented strand board. MRC is further investigating the feasibility of certain applications through pilot studies
Recycled Foam Works in Concrete
Posted: December 2021
Category: New Markets
In an 18-month study at UCLA, researchers found that chemically recycled polyurethane mattress foam can be used to make concrete with less energy consumption than traditional concrete production methods. The results of two MRC-funded studies at UCLA were released in December 2021.
Researchers determined the upcycled polyurethane foam can be combined with naturally occurring zeolite minerals to produce high strength composites with properties comparable to ordinary Portland cement. The composites have better flexural strength and crack resistance and may be suitable for use in cast concrete and other products such as concrete sound barriers, benches, etc. The research also showed that the recycled foam actually outperformed virgin polyurethane materials.
A patent application was also filed in October 2021 for the process to add upcycled polyurethane foam to concrete.
New Foam Made from Recycled Foam
Posted: December 2021
Category: New Markets
In an 18-month study at UCLA, researchers demonstrated the viability of upcycled polyurethane products, obtained from mattress foam, as a partial replacement for virgin polyol chemicals in the production of new foam products.
A paper was presented in 2021 at the Polyurethane Technical Conference in Denver.
Counting Study: The Queens are Most Recycled
Posted: December 2021
Category: Technical Documents
In 2021, MRC commissioned a mattress type counting and a composition study as the initial steps in conducting a Life Cycle Analysis (LCA). This LCA will quantify the positive and negative environmental impacts of the California program. The survey of a California recycler found that queen-size mattresses were the most frequently recycled. This counts and composition study was delivered in December 2021.
Mattress Type and Composition Analysis
Posted: December 2021
Category: Technical Documents
In 2021, MRC commissioned a mattress type counting and a composition study as the initial steps in conducting a Life Cycle Analysis (LCA). The survey of a California recycler found that Bonnell springs and pocket coil springs together compose 54% of all mattress types in the survey. This composition report was delivered in December 2021.
Study Explores Waste After Recycling
Posted: August 2021
Category: Technical Documents
MRC commissioned a waste characterization study of the residual material generated California mattress recyclers to quantify what mattress components are landfilled. The August 2021 report found the top three most prevalent waste categories as a percentage of total waste are shoddy felt pad (22.0%), mixed non-woven fibers (19.8%) and quilt panels (17.3%).
Recycling Pocketed Coils
Posted: October 2020
Category: Recycling Efficiency
MRC has completed a sponsored research project with Wisconsin-based Knoble Design LLC to explore a novel approach for recycling pocketed coils, resulting in the successful construction of a small-scale machine demonstrating the approach. Project findings are detailed in a final October 2020 non-confidential report and demonstration video.
Study Finds Limited Uses of Shoddy Pads
Posted: October 2020
Category: New Markets
MRC contracted with GHD to explore the potential use of recycled mattress shoddy pad materials in civil engineering applications. We wanted to understand whether the fibrous nature of the material might be useful to filter storm water or control soil erosion. After receiving the October 2020 report, MRC decided to abandon the project because additional testing needed to determine if the product was appropriate for in-ground applications was cost prohibitive.
Study Reviews Energy Potential of Fluff
Posted: May 2020
Category: Technical Documents
In May 2020, MRC prepared a composite sample of shredded mattress quilt, foam, cotton, shoddy and other textiles. This sample was tested for composition, BTU (heat value), burn residuals and suitability for use as a substitute fuel which is a better end use than landfill.
Study of Mattress Metals for Secondary Use
Posted: May 2020
Category: Technical Documents
In May 2020, MRC collected samples of mattress metals to test for analytical composition and hardness to assist mattress recyclers, metal brokers and smelters to best prepare, process and recycle these metals for secondary markets.
Report Evaluates Transportation Logistics
Deadline: May 2020
Category: Recycling Efficiency
In May 2020, MRC completed a transportation study to evaluate the current performance of its logistics and supply chain to continuously improve operations and efficiency.
Lean Assessment Report Reviews Recyclers
Posted: April 2020
Category: Technical Documents
MRC completed lean manufacturing assessments for 12 mattress recycling companies in April 2020. Each facility received a confidential report detailing the results of the analysis, recommendations for improvement and associated potential impacts.
2019 Study Looks at Reusing Recycled Wood
Posted: November 2019
Category: New Markets
MRC wanted to understand the capacity and viability of secondary wood markets in California and a study that was completed in November 2019 identified sustainable and financially viable outlets for wood from dismantled box springs.
The Average Age Mattress MRC Receives is 11
Posted: April 2019
Category: Technical Documents
MRC contracted with MSW Consultants to understand the average age of discarded mattresses and box springs for forecasting purposes. Using manufacturing date tags collected at recycling facilities in each MRC state; MSW determined in the April 2019 study that the average of discarded units is 11.2 years.