Circularity feasibility study of the increase of recycled content within foamed bio-based polyurethane formulations from high energy efficient window frames and insulation products
SECTOR
MATERIALS FOR ENERGY EFFICIENT BUILDINGS
CHALLENGE
Polyurethane production relies heavily on virgin fossil-based polyols, causing high emissions and resource depletion. Mechanical recycling is limited (up to 10% recycled content) and unsuitable for foamed applications, while the market for chemically recycled polyols remains immature, with scarce data, inconsistent quality, and limited large-scale availability. To be competitive, recycled options must be 5–10% cheaper than virgin ones.
The main challenge is to validate whether chemically recycled polyols can be integrated into INDRESMAT’s bioPUR formulations while ensuring technical performance, economic viability, regulatory compliance, higher circularity, and lower carbon footprint.
SOLUTION
The Up2BioPUR project proposed a solution by integrating chemically recycled polyols into INDRESMAT’s bioPolyurethane (bioPUR) formulations for windows and insulation foams. This approach could enable the company to reach up to 42% recycled content, while maintaining comparable technical performance to virgin-based polyols.
CIRCULAR ECONOMY STRATEGIES/BUSINESS MODEL IMPLEMENTED
In Up2BioPUR, INDRESMAT is implementing a circular approach to polyurethane production by progressively replacing virgin fossil-based polyols with recycled alternatives. By prioritising suppliers of chemically recycled polyols, the company is narrowing resource loops, reducing dependency on finite raw materials.
The project is also closing loops, reintroducing post-consumer and post-industrial polyurethane waste into new formulations through chemical recycling. Lab-scale tests are showing that such recycled inputs can be reintegrated without compromising density, reactivity, or foaming behaviour. In this way, recycled content is slowing down material cycles while ensuring durability and performance consistent with market expectations.
At the same time, the strategy is regenerating loops, as the adoption of recycled polyols is diverting waste streams from landfills and incineration, while lowering greenhouse gas emissions compared to virgin production. This integrated approach—narrowing, closing, slowing, and regenerating resource loops—is underpinning INDRESMAT’s circular business model. The expected outcome is achieving up to 42% recycled content in bioPUR foams and defining a roadmap for industrial scale-up, offering a replicable and scalable example for the construction sector.
IMPACT
Environmental impact By integrating chemically recycled polyols into bioPUR formulations, INDRESMAT is reducing the dependency on virgin raw materials and lowering the overall carbon footprint of polyurethane products. Preliminary assessments are showing that adopting up to 42% recycled content could reduce CO₂ emissions by around 23.5% compared to current formulations.
Economic impact By sourcing recycled polyols from European suppliers and validating their integration into formulations, INDRESMAT is creating opportunities for cost optimisation and supply chain resilience. Market analysis is indicating that the substitution of virgin polyols could generate more than €100,000 in potential savings over two years, while mitigating the risks of volatile fossil-based raw material prices.
Social impact
Through the Up2BioPUR initiative, INDRESMAT is fostering innovation, raising awareness among stakeholders, and promoting circularity within the construction and chemical sectors. The project is already engaging with more than 15 stakeholders across the value chain, building knowledge-sharing and collaboration platforms. In the medium term, this circular transition could be generating new high-qualified jobs in R&D, production, and supply chain management, strengthening Europe’s industrial resilience after recent crises.
KEY TAKEAWAY
By integrating chemically recycled polyols into bioPUR formulations, INDRESMAT is demonstrating how polyurethane can become a circular, low-carbon material for construction. This approach could achieve over 40% recycled content, cut CO₂ emissions by nearly 25%, and reduce costs, proving that sustainability and competitiveness can go hand in hand.