As the world shifts towards a circular economy, industries across the board are rethinking how they handle waste and design their products. The mattress industry is no exception. In a recent episode of the Ellie Talks Podcast, Ruben Demets, Recycling Manager at BekaertDeslee, a pioneer in sleep solutions, shared his insights on the challenges and opportunities in mattress recycling, sustainable design, and the future of the industry.
Key insights of the Episode
- It’s all about striking the perfect balance between customer needs and enhanced recyclability.
- Urgent need for a legislative framework: supportive legislation will enhance recycling efficiency and innovation.
- Collaboration is essential: partnerships across the value chain are vital for creating a sustainable circular economy (in the mattress industry.)
- Recycling and new technologies: new technologies will facilitate the future of product recycling f.ex the digital passport
Prioritizing recycling
Ruben discusses BekaertDeslee’s commitment to sustainability through its dedicated Recycling Manager position, which is not always a given because companies are too small or lack the budget for it. This strategic investment allows BekaertDeslee to focus on the recycling of its own products, particularly mattress textiles and covers. Ruben notes: “There are currently no ready-made solutions for mattress recycling”, which makes it essential for the company to explore and develop the best approaches tailored to their products. The importance of recyclability is not just a passing trend; it is an urgent necessity. Upcoming legislation will require products to be recyclable and may even mandate a specific percentage of recycled content, raising the stakes significantly. By proactively addressing these challenges, BekaertDeslee is positioning itself to meet future regulatory demands.
Tackling the recycling challenge in mattresses
Recycling mattresses is not easy. Although EPR systems are being established to collect and dismantle mattresses, their textile components, such as mattress covers, are not being recycled and often (still) end up incinerated or used in applications like pillow stuffing. BekaertDeslee is working hard to change this narrative, focusing on improving the recyclability of its products. “We are really trying to get involved in what is the best solution for our products,” Ruben explains.
Additionally, the product team is actively monitoring the recyclability of their products, assessing both whether a product can be recycled and the amount of recycled content it contains. However, the lack of clear definitions around recyclability poses challenges, as various recycling options and technologies come with different requirements. This complexity makes it difficult to establish a streamlined recycling system that meets industry standards.
Navigating the complexities of recycling
One of the biggest hurdles in textile recycling is the diversity of materials and finishes used. Mattresses are often composite structures made up of various materials like polyester, cotton, and chemicals that complicate the recycling process. This complexity requires innovative approaches in both product design and waste management.
BekaertDeslee is actively seeking solutions to create products that are easier to recycle. “We already have solutions ready to deliver 100% monomaterial products,” Ruben notes, which simplify the recycling process. They are also exploring alternatives to harmful chemicals that can interfere with recycling without compromising the quality of the recycled material. Additionally, the design team is considering eliminating zippers altogether, opting for zipperless covers that can fit directly over the foam. This change not only enhances recyclability at the end of the product’s life but also allows for easier separation of materials, increasing the likelihood of successful recycling.
Collaborating for success: The role of partnerships
In the pursuit of a more circular mattress industry, partnerships play a crucial role. BekaertDeslee, as a B2B company, recognizes that sustainability cannot be achieved alone; it requires engaging the entire value chain. Ruben emphasizes the importance of collaborating with suppliers and customers, as the textile value chain is long and complex. “We really have to find the right collaborations, the right partnerships to set up a circular value chain for our products and waste materials,” he states. This collaboration is vital not only for sourcing yarns with lower carbon footprints but also for educating mattress assemblers about the cost implications of incorporating recycled content into their products. Despite the challenges posed by a commodity market where cost is a significant concern, BekaertDeslee is committed to guiding its customers, using their expert knowledge on the recycling topic, toward more sustainable and circular choices whilst advocating for legislation that creates a level playing field to increase gradually recycled content in products.
Design for recycling and the future of circularity
Designing products with recycling in mind is an essential part of creating a circular economy. BekaertDeslee is actively working with its design team to incorporate recyclable materials and innovative designs, such as zipperless covers, that simplify recycling. Ruben emphasizes the challenge of balancing the push for monomaterials and recyclability with the diverse requirements of their clients. While the goal is to create products that are easier to recycle, the need to meet client specifications can complicate this process. This balancing act becomes even more challenging because of the lack of clear definitions regarding recyclability and the constantly evolving legislation.
Looking to the future, BekaertDeslee is focusing on integrating digital product passports that can track a product’s lifecycle, making it easier to recycle once it reaches the end of its life. “For mattresses, it’s quite difficult because they often lie at people’s homes for eight or ten years,” Ruben explains. But by creating transparency and traceability, the company aims to ensure products can be easily recycled, even years down the line.
Innovating towards a circular supply chain
BekaertDeslee is exploring technical solutions for closed-loop recycling, specifically focusing on transforming textile waste back into yarn (still on lab scale). While current technologies for textile-to-textile recycling are still under development, the company collaborates closely with suppliers and chemical companies to assess the potential of their waste streams. In the meantime, BekaertDeslee is dedicated to collecting and sorting their waste into various fractions to create value. Currently, BekaertDeslee’s waste sorting and recycling efforts are focused in Europe, but the company plans to expand these initiatives globally.
Ruben is optimistic about the future. “A lot of efforts are going into making yarn from waste,” he shares. The ultimate goal is to create a truly circular supply chain where waste materials are collected, recycled, and reintroduced into new products.
A call to policymakers
Ruben’s message to policymakers is clear: involve the right experts. As recycling technologies evolve, it’s crucial that legislation supports, rather than hinders, companies in their sustainability efforts. “You need engineers and material scientists to set up those value chains and make the right designs,” Ruben urges. Policymakers should work closely with industry experts to create legislation that fosters innovation in recycling and sustainable design.
Looking ahead
BekaertDeslee is pioneering mattress recycling through innovation, collaboration, and a commitment to sustainability. As the company continues to develop new technologies and designs, it’s clear that the future of mattress recycling is interesting. Whether through monomaterial solutions, digital product passports, or global waste management systems, the path to a circular mattress industry is being paved by pioneers like BekaertDeslee. In the coming years, Ruben hopes to see even greater progress: “Finding close collaborations and partnerships to really set up a circular value chain for our products, for our waste materials—this is something that should be developed and will be necessary.” The future of mattress recycling is not just about solving today’s challenges, it’s about shaping tomorrow’s solutions.
