In a context of increasing regulatory pressure and a transition toward a circular economy, the recycling of polyurethane (PU) and polyisocyanurate (PIR) foams represents a major challenge for many industrial sectors (construction, transport, household appliances, etc.). These materials, which are difficult to recycle mechanically, require alternative approaches to enable their reintegration into circular value chains.

Materia Nova is developing an innovative chemical recycling technology based on a continuous, solvent-free process, currently at pilot stage (TRL 5). A patent application for this process was filed in 2024.

Technical features

The developed process enables:

One-step depolymerization in just a few minutes,
Production of high-quality recycled polyols,
Homogeneous molecular weight of the resulting products,
Direct reuse in new foam formulations,
Improved energy efficiency compared to conventional methods.

These results open up concrete prospects for closed-loop recycling of PU/PIR foams, with precise control over the physicochemical properties of the recovered polyols.

Results and industrial validation

The process has been evaluated within the UP-Plastics and CIRCOPLAT projects, with support from the Walloon Region. Several industrial partners have tested the technology with their own waste streams, enabling the integration of 20 to 30% recycled polyols into new formulations. Work is ongoing to adjust polyol characteristics according to the technical specifications of final products.

Challenges and outlook

This technology is part of a research dynamic aligned with European objectives for the circularity of complex plastics. It addresses several priorities identified in the Horizon Europe 2026–2027 calls, particularly those related to advanced chemical recycling and resource optimization in production.

Materia Nova continues to optimize the process in collaboration with academic and industrial partners and remains open to new tests on real waste streams, in a co-development approach.

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