Brussels, 30 September 2026 – 10.00 CET
EURO-MOULDERS, the European Association of Manufacturers of Moulded Polyurethane Parts for the Automotive Industry, has published a new study exploring the recyclability of polyurethane (PU) foam recovered from end-of-life vehicles (ELVs) in the context of the EU End-of-Life Vehicles Regulation (ELVR). With the support of 11 organisations, including LSH Lubecker Schrotthandel, Herfel Entsorgung, Federal Eco Foam, H&S Anlagentechnik, Analyticon Instruments, Adient Seating, Proseat, Toyota Boshoku Europe, Toscana Gomma, the Environmental Campus Birkenfeld, and NEVEON Germany, the study demonstrates the technical feasibility of both mechanical and chemical recycling of PU foam from ELVs.
The European Union has reached a final agreement on the provisions of a new ELVR, representing a significant transition from the previous Directives to a unified and directly applicable legal framework. The Regulation is intended to support the transition towards a circular economy in the automotive sector by introducing stringent requirements throughout the entire vehicle lifecycle, from design and production through reuse and recycling to final treatment at end of life. Key provisions include mandatory recycled content targets for plastics and strengthen Extended Producer Responsibility.
In this context, EURO-MOULDERS has issued a research on the recyclability of polyurethane foam from end-of-life vehicles, led by its Technical Chairman Mr. Stephan Wendel. This is particularly relevant as very little research on the possibility of removing PU from ELVs seats for recycling has been carried out until now, while it is estimated that a passenger car contains between 24-28kg of PU, most of which is flexible PU foam used as cushioning in seats (8-10kg). Considering that nearly 11 million passenger cars were produced in 2025, this corresponds to approximately 90-110kt of PU foam in seats and a total of PU content of approximately 260-310kt.
The research evaluates both post-industrial and post-consumer PU foam and explores three primary recycling pathways:
- Mechanical recycling: cleaned ELV foam flakes that are free from metal components, hard plastics, fleece and other contaminants can be bonded to produce sports mats. Trials at Federal Eco Foam demonstrated that these flakes can be processed in the same manner as standard foam flakes, with no identified issues relating to legacy substances or compounds on the REACH Candidate List.
- Chemical recycling (depolymerisation): PU foam can be chemically converted into precursors known as recycled polyols. Contaminants such as EPP and PES fleece adversely affect the process. Further optimisation is required, particularly with respect to odour management and the cell morphology of r-polyol-based foams.
- Thermochemical recycling (HTC Process): hydrothermal carbonisation (HTC) was investigated as a potential treatment route for unsorted Automotive Shredder Residue (ASR). Preliminary trials demonstrated an ASR volume reduction of approximately 85%, producing a dry, free-flowing carbonaceous material suitable for subsequent gasification or pyrolysis.
“There is a persistent narrative that polyurethane foam, the second most prevalent plastic in cars today, is not recyclable. This has been proved wrong for foam in mattresses years ago already. The EURO-MOULDERS study now proves that PU foam from car seats is recyclable too. Is it easy? No, the supply chain has a lot of work to do on enabling conditions like enhanced dismantling and sorting technologies and car seat design built for recycling. But the circular potential of the material is clearly there”
– Michel Baumgartner, Secretary General
Current processes for converting PU foam into r-polyols require clean and dry PU feedstock. Improvements are therefore needed in the storage and dismantling of ELVs to enable the recovery of sufficiently high-quality and process-ready PU foam. Improved design for dismantling could also facilitate more efficient recovery of clean foam while reducing material losses.
For more information, please contact Constance Rossi, Communications Officer (c.rossi@europur.org)
About EURO-MOULDERS
EURO-MOULDERS is the European Association of Manufacturers of Moulded Polyurethane Parts for the Automotive Industry. Our members produce moulded polyurethane foams for seat cushions in 28 plants in 13 countries. They collectively employ over 10,000 people. The EU’s total production of moulded foam for the automotive sector is around 150,000 tonnes per year. Moulded polyurethane (PU) foam, thanks to its unique properties, is today by far the preferred cushioning material for automotive seating, with a market share of well over 90%.