Dow Chemical, Mobius Complete Plastics Recycling Project

Dow Chemical Co. and Mobius Technologies have completed the installation of a polyurethane recycling system at Dow's Technical Development Center in Meyrin, Switzerland. The technology gives polyurethane foam producers an economical way to turn scrap-foam into a replacement for virgin chemicals, reducing the costs of producing new foam.

"We anticipate that customers will be pleased with the capabilities of the machine. We have channeled a lot of effort into this project in order to demonstrate that foam recycling can be economically viable," says Steven English, business development director, Dow Polyurethanes. "A considerable amount of scrap is made whenever flexible slab and molded foams are produced. The scrap has some value when it is reused for rebonding applications, such as carpet padding and NVH (noise/vibration/harshness) cushioning for automobiles. However, the supply of scrap usually outstrips demand, so this value fluctuates. Moreover, much of the scrap produced is unsuitable for these applications, and must be directed to a landfill."

The Mobius Technologies recycling system allows scrap to be used as a substitute for virgin chemicals in the production of new foam, offering a viable supplement to rebond applications.

"By reusing the foam, customers reduce manufacturing costs," says Martin Dawson, COO, Mobius Technologies. "This is important because alternative scrap foam markets are in structural decline. Plus, to meet the EU directive, foam producers are in need of a solution that doesn't just make good environmental sense, but also makes good business sense."

The demonstration model is one of two units in operation in the world right now, the other being in commercial use in the United States.

"Customers that have seen it, clearly understand both its operational and its strategic value," says English. "As there is no reduction in properties compared with the original foam, they get a quality product at a lower price, and a way to create value from their scrap. We anticipate that this technology will be attractive on a global basis, and that polyurethane foam manufacturers worldwide will have an interest in utilizing this technology and will visit the Meyrin facility for a demonstration of its capability."