Evonik is accelerating efforts to transform polyurethane (PU) foam waste into valuable raw materials. At its Hanau site in Germany, the company is developing a chemical recycling process that aims to significantly reduce landfill disposal. In support of this initiative, the state of Hesse has provided funding to strengthen circular economy innovation. During a visit to the Wolfgang Industrial Park, Kaweh Mansoori, Hessian Minister for Economic Affairs, Energy, Transport, Housing and Rural Areas, formally presented the grant for further development of the technology.
From Waste to Raw Material: Closing the PU Loop
Every year, Germany generates thousands of tons of PU foam waste from discarded mattresses, furniture, and car seats. Instead of sending this material to landfill, Evonik is working to keep it in circulation. The company breaks down PU foam into its basic chemical building blocks using a newly developed hydrolysis process. As a result, the recovered materials can be reused to manufacture high-quality products, thereby enabling a true circular value chain.
As per the Evonik press release, this approach demonstrates how chemical recycling can turn complex plastic waste streams into high-quality secondary raw materials, supporting both resource efficiency and sustainability goals.
Pilot Plant in Hanau Demonstrates Industrial Feasibility
What began as a laboratory-scale innovation has now moved into continuous operation. Evonik is currently running a pilot plant at its Hanau site to validate the process under real-world conditions. Moreover, the company aims to scale the technology to industrial levels. This transition is expected to reduce reliance on fossil-based raw materials while also lowering the CO₂ footprint of PU production.
Technology Center to Strengthen Chemical Recycling Research
In addition, Evonik plans to establish a dedicated technology center at the Wolfgang Industrial Park. This facility will focus on advancing chemical recycling processes for plastics. It will also work on key upstream and downstream steps such as shredding, pelletizing, grinding, filtration, and centrifugation. Furthermore, the center will explore how to efficiently process and utilize additional waste streams, thereby expanding the scope of circular solutions.
Strong Policy Support for Industrial Innovation
According to Thomas Wessel, Chief Human Resources Officer and Labor Director at Evonik, public support plays a crucial role in accelerating industrial innovation. He emphasized that funding from the state of Hesse arrives at an important time, helping bring sustainable technologies into commercial application more quickly. Consequently, Evonik is better positioned to scale its recycling solutions and strengthen its sustainability roadmap.
Government Perspective: Linking Industry and Climate Goals
Kaweh Mansoori highlighted that PU foam recycling demonstrates how industrial value creation and climate protection can work together. He noted that the state of Hesse actively supports projects that bridge the gap between research and industrial application. In doing so, the region strengthens its position as a hub for sustainable industrial development.
Strengthening the Wolfgang Industrial Park Ecosystem
The project also holds strategic importance for the Wolfgang Industrial Park in Hanau. Site Manager Kerstin Oberhaus explained that the PU recycling process represents a concrete step toward recovering polyurethane components at virgin-quality levels. Additionally, she emphasized that these developments reinforce the site’s role as an innovation and scaling hub.
Expanding into Electrochemistry for Future Technologies
Looking ahead, Evonik is also planning an electrochemistry hub within the industrial park. This center will support the scaling of electrochemical processes for applications such as battery materials, membranes, and catalysts. By collaborating closely with industry partners, academic institutions, and startups, the hub aims to accelerate the commercialization of next-generation sustainable technologies.
