POSSIBLE Project Finds Success in Mechanical Recycling of Rigid PU, GFRP

Why It Matters

Mechanical recycling integrates waste PU and GFRP into current production without costly new equipment, accelerating circularity in the thermoset market and delivering immediate cost and carbon savings.

Key Takeaways

• Cannon demonstrates 3% recycled PU powder in foam
• Up to 40% recycled granules integrated via Interwet-LFI
• Process uses existing high‑pressure mixing heads, no new lines
• Thermal conductivity rises only 4% with 3% recycled content
• Screw conveyor handles granules up to 100 g/s flow

Pulse Analysis

The polyurethane and glass‑fiber‑reinforced polymer sectors have long struggled with end‑of‑life management because cross‑linked chemistries resist conventional mechanical recycling. Chemical depolymerisation routes exist, but they remain laboratory‑scale, costly, and often incompatible with high‑throughput manufacturing. In Europe, the EU recovery fund has earmarked resources for scalable, low‑impact solutions, prompting collaborations like the POSSIBLE project to explore alternatives that fit within existing plant footprints.

Cannon’s approach sidesteps the need for new reactors by leveraging its FPL 36 IW high‑pressure mixing head. In the first route, rigid foam is milled into fine (PU‑A) and coarse (PU‑B) powders, then blended into the polyol stream at up to 20 % of the polyol weight, creating a stable slurry even at viscosities above 10,000 mPa·s. Panels produced with 3 % recycled powder show only a 4 % increase in thermal conductivity, preserving insulation performance. The second route transforms waste PU and GFRP into granules that are fed directly into the Interwet‑LFI system via a flexible screw conveyor, achieving uniform filler distribution and enabling formulations with up to 40 % recycled content.

For manufacturers, the significance is twofold: environmental compliance and cost efficiency. By integrating recycled feedstock without redesigning production lines, firms can reduce raw‑material expenses and lower their carbon footprint, aligning with tightening EU sustainability mandates. The commercial rollout anticipated by Cannon could set a new industry standard for thermoset circularity, encouraging broader adoption of mechanical recycling across the polyurethane market and stimulating further investment in sustainable manufacturing technologies.