Cost–Benefit Analysis and System-Level Evaluation of Recycling Metallized Biaxially Oriented Polypropylene Film as a Filler in Polyurethane Foam

This study presents a comprehensive evaluation of the economic viability, environmental impact, and social value of valorizing metallized biaxially oriented polypropylene (BOP) film waste as a nonreactive filler in flexible polyurethane (PU) foam synthesis. Given the challenges of recycling complex multilayer films and the high carbon footprint of virgin-polyol-based PU production, this approach offers a circular solution to reduce petrochemical dependency and landfill-bound waste. Through a multiscalar cost–benefit analysis (CBA) and social impact assessment (SIA), the integration of up to 15 wt % BOP filler is shown to deliver material cost savings of approximately $300 per metric ton while reducing lifecycle greenhouse gas emissions by over 90% compared to incineration. Additionally, decentralized waste valorization supports the creation of up to 210 direct and indirect jobs per 10,000 tons of BOP waste processed annually, enhancing inclusive labor markets in developing regions. Despite technical and regulatory limitations such as filler dispersion, aesthetic constraints, and a lack of harmonized standards, the strategy aligns with key Sustainable Development Goals and presents scalable pathways for industrial decarbonization and Environmental, Social, and Governance (ESG) performance enhancement. The findings position BOP-recycled PU foam as a viable, low-carbon innovation in polymer circularity and sustainable materials management.