Research: Completed Reports
Treating Mattress Foam Increases Its Potential in Oil Spill Cleanups
Posted: November 2024
Category: New Markets
Modified polyurethane mattress foam can absorb oil and perhaps other chemicals from contaminated water, according to MRC-funded research at Arizona State University (ASU). Chemically treating the foam shows promise as an innovative and cost-effective solution for oil spill cleanup applications. The ASU team used a variety of techniques to alter the surface chemistry of foam, which changed its ability to absorb more oil and less water. These results were encouraging. Modified recycled foams may also separate other chemicals from water.
Vitrimerization: A novel new process to recycle polyurethane foam
Posted: September 2024
Category: New Markets
In a project sponsored by MRC, Edge Global Innovation (EGI) developed a new process that converts polyurethane foam into moldable elastomers with excellent properties. The resulting products can be formulated for use in applications including shoe soles, gaskets, rubber mats, rubber hoses, marine dock bumpers and many other end uses. The thermochemical conversion process is energy efficient and does not use solvents or added catalysts. EGI has formed a subsidiary, Vitricycle LLC to oversee commercialization and they are seeking development partners. Additional information can be found in the technical report.
Pilot Test of Compressing Trailer Saves 26%
Posted: August 2024
Category: Recycling Efficiency
Due to their low bulk density, transportation of mattresses from collection sites to recyclers is a significant contributor to the total cost of recycling. In a joint project with G&G Transport, a specialized trailer was developed that compresses mattresses by at least 50% of their original volume. In the California test trials, the project team demonstrated that mattresses could be safely and economically compressed without impacting recyclability. Commercial scale shipments using the first-generation trailer resulted in a 26% reduction in total transportation costs. A larger second-generation trailer, which is under development, has the potential to reduce total transportation costs by 45%.
Biodegradable Composites Made with Recycled Mattress Cotton
Posted: July 2024
Category: New Markets
An MRC-funded feasibility study exploring fiber-reinforced composites made with recycled mattress cotton and a biodegradable polymer was conducted by a research team led by Dr. Sunidhi Mehta at West Virginia University. In biodegradation studies, the team demonstrated the composites decomposed quickly in a composting environment without harmful byproducts. According to the American Composites Manufacturers Association, the industry trade association dedicated to advancing sustainable solutions, there are many composite materials applications.
LCA Independent Review Confirms the Substantial Environmental Benefits of Mattress Recycling
Posted: June 2024
Category: Recycling Efficiency
MRC contracted with Scope 3 Consulting to conduct a life cycle analysis (LCA) of our California operations in 2021. 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 greenhouse gases. An independent review by an external panel of industry experts and an LCA practitioner confirmed the findings in the original report. The LCA is now a living document which establishes a benchmark by which future technologies will be evaluated. The Annex, which reflects today’s environment, shows further environmental benefits over the original work.
UCLA Foam Characteristics Research
Posted: April 2024
Category: Technical Documents
Researchers directed by Dr. Samanvaya Srivastava at UCLA’s Chemical and Biomolecular Engineering Department tested post-consumer mattress foam to understand the characteristics and variability of sample density, chemical composition, thermal, and mechanical properties. The MRC-funded project provides important information essential to tailoring recycling strategies for different foam types.
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.
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.