Chemical recycling of polyurethane foam

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One of the polyurethane recycling pioneers in Europe

We are building the first plant in Spain to chemically recycle polyurethane foam at our Puertollano Industrial Complex with a capacity to treat 2,000 tonnes of this type of waste per year. This is equal to 200,000 mattresses that lined up in a row would measure 235 miles in length. Approximately, this would cover the distance between the cities of Madrid and Valencia. The plant will start up by the end of 2023 and will involve an investment of €12 million.

Polyurethane foam, the main component in mattresses, couches, and vehicle seats, among other uses, is considered bulky waste due to its very low density and large size. This makes it one of the materials with the lowest recycling rate once it has reached the end of its useful life.

Our Repsol Reciclex® polyols range

With this new process, we'll produce circular Repsol Reciclex® polyols, which closes the loop for this kind of waste by giving it a new life.

It's a new recycled polyol that is produced from post-consumer polyurethane foam in mattresses. This polyol can be incorporated into regular processes for new foam production, thus closing the cycle of the circular economy of this material.

Expanding our partnerships to produce polyols

We signed an agreement with RAMPF Eco Solutions, a German company expert in chemical solutions for producing alternative high-quality polyols, which grants us exclusivity throughout Europe to develop and build new flexible polyol recycling plants using various sources and qualities of post-consumer polyurethane waste.

This agreement makes it possible for both companies to join forces, our extensive recycling knowledge and experience, as well as our polyol production capacity and engineering. By making the most of these synergies, both of our companies will be able to promote the efficient recycling of flexible foam.

This partnership demonstrates our goal to transform our industrial complexes and turn them into multi-energy hubs capable of producing products with a low, zero, or even negative carbon footprint. This also shows our ambition to close the loop upon recycling these essential products by offering sustainable solutions both for polyurethane converters and end consumers. 

The project in figures



of external waste processed at our facilities equal to 200,000 mattresses



of circular polyols from our Repsol Reciclex® range

€12 M

invested in the plant


Expected start-up year

Circular benefits

  • Recycling alternative for polyurethane, a material that currently has a very low rate of recycling, thus decreasing the amount that ends up in landfills.
  • One of the pioneers in Europe and the first plant with these characteristics in Spain.
  • Opening new markets to offer our clients innovative and more sustainable solutions, like circular polyols.
  • Lower consumption of virgin raw materials, and therefore, leading to resource savings.
  • Reduction of direct and indirect CO2 emissions versus using virgin raw materials, thus supporting the goal of reaching net zero emissions by 2050, as announced in November 2019.
Mano de mujer apoyada sobre un colchón blanco.

Classification by key lines and value chain

Our circular economy projects are aligned with the key lines of our strategy and are present throughout our entire value chain, from obtaining raw materials to commercializing products and services. 

Classification by key lines and value chain