Mechanical Recycling for Sustainable Polyurethane Foams: a Life Cycle Assessment Study

Polyurethane (PU) is a versatile and widely used polymer, essential in applications such as thermal insulation, furniture cushioning, and transportation. However, while its functional benefits are well-established, its end-of-life management remains a critical challenge. Due to its low biodegradability and complex composition, traditional disposal methods like landfilling and incineration pose severe environmental challenges and are increasingly unsustainable. To address these challenges, this study investigates the feasibility of mechanical recycling as a sustainable strategy for managing PU foam waste generated during the decommissioning of buses and trains. To evaluate the environmental implications of this recycling pathway, a comprehensive Life Cycle Assessment (LCA) was conducted, covering all stages from waste collection and mechanical treatment to the production of new foam materials. The results highlight the potential of mechanical recycling as an effective and sustainable approach to PU foam waste management, with relevance to the transportation sector. Integrating such recycling processes into conventional industrial workflows can significantly contribute to meeting waste reduction targets, improve the environmental footprint of polyurethane production, and promote stronger adherence to circular economy principles.