2026.02.10

INOAC has established a comprehensive process that enables the re-materialization of polyurethane foam offcuts generated during its manufacturing processes and their re-foaming into recycled polyurethane foam through innovative technological developments.
This chemical recycling technology is characterized by the ability to complete all processes--from re‑materialization to final product manufacturing--entirely in‑house by utilizing a demonstration unit independently developed by the company.

Polyurethane foam is a thermosetting resin that is difficult to recycle back into raw materials. Furthermore, in Japan, the business domains of raw material manufacturers and foam manufacturers are clearly divided due to the high level of specialization required. These two factors have long posed major barriers to establishing a comprehensive chemical recycling system for polyurethane foam in the country. Our newly developed chemical recycling technology overcomes this barrier by introducing a custom-built demonstration unit that chemically decomposes and regenerates the offcuts generated in our own manufacturing processes. This has enabled us to establish a new circular model in which the entire process--from raw material regeneration to foam production--can be completed solely within our own operations. It has also been confirmed that the regenerated polyurethane foam possesses physical properties comparable to those of our existing materials.

Development Background

Thus far, we have been engaged in the production of Mixel, a material‑recycled product made by pulverizing and molding offcuts generated during our manufacturing processes. However, due to the characteristics of the material, some offcuts are not suitable for material recycling, and the necessity to dispose of a portion of them had long been a challenge. Driven by a strong commitment to "recycling all offcuts generated in our manufacturing processes," we accelerated our research into chemical recycling. As a result of repeated optimization of raw material formulations and equipment optimized for our own products, we successfully achieved re‑materialization in our demonstration tests.

Name of the Product

We have named the polyurethane foam produced using this regenerated raw material "rePURous™."

"The name combines "PUR," representing polyurethane foam, with "re," meaning regeneration, expressing our commitment to reborn, circularity, and connection. We position "rePURous" as a brand that representing our commitment to environmental responsibility. By enhancing awareness of recycled materials and creating added value, we will continue to communicate our sincere dedication to reducing environmental impact.

*"rePURous" is currently pending trademark registration.

Future Outlook

We are currently working to establish a mass‑production framework using offcuts generated within our own facilities. Looking ahead, we will pursue further technological development to enable the recycling of post‑consumer polyurethane foam that has reached the end of its life in the market.
This includes examining collection and disassembling methods for mattresses, as we aim to further expand resource circulation.

Furthermore, since polyurethane foam is derived from finite fossil resources, we will actively promote the use of regenerated raw materials, thereby contributing to the reduction of fossil fuel consumption and the decrease of greenhouse gas (GHG) emissions. We recognize our responsibility as a manufacturer that utilizes valuable resources, and moving forward, we will work together with local governments and other polyurethane foam manufacturers to build a circular model that encompasses everything from collection to recycling. Through these efforts, we aim to contribute to the realization of Green Transformation (GX).