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Advances in Mattress Foam Recycling. Mike Gallagher and Karl Haider, Mattress Recycling Council.
Developing robust, commercially viable end markets for recovered polyurethane foam remains one of the most significant challenges to long-term scaling for mattress recycling operations. This presentation provides an updated assessment of polyurethane foam recycling rates in the United States and the technical barriers that continue to limit higher recovery and reuse.
MRC will outline its current market development portfolio, including the expansion of vitrimer‑based technologies into new product applications, advancements in processing enabled by novel dynamic exchange catalysts, and progress in building and construction markets that leverage foam’s inherent insulation and acoustic performance attributes. The session also highlights recent developments in surface-functionalization technologies aimed at improving value in downstream applications.
The presentation concludes with an overview of the newly established Foam Technical Working Group, an interdisciplinary collaboration designed to integrate industry expertise, accelerate innovation, and strengthen MRC’s long‑term foam recycling research strategy.
Speaker Biography: Mike is a materials scientist and a chemical industry consultant focused on supporting sustainable innovation. He has worked with the Mattress Recycling Council since 2018, helping to develop and manage its Research Program. After a 38-year career in the polymer industry, Mike retired from Covestro LLC, (formerly Bayer MaterialScience) in 2017. In his last position, he headed the North American Innovation Office where he was responsible for the development and management of the region’s innovation strategy working closely with all business units.
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