Recycling with PURrecy

From waste to technical insulation

In the green transition, there is increased focus on the importance of insulating technical installations. It costs energy to heat liquids and similarly to cool them down. Effective insulation of pipelines is therefore a key ingredient in the recipe for more sustainable production and operation.

Pipe insulation using cellular foam such as PUR and PIR offers remarkable insulation capabilities and a long lifespan, as it does not absorb moisture or collapse over time. When using PUR and PIR insulation, heat and cold loss are significantly reduced compared to traditional insulation types, thus saving unnecessary CO2 emissions.

However, the production of PUR insulation generates a significant amount of waste. This waste cannot be immediately recycled and therefore needs to be disposed of. The disposal of PUR can emit up to 4 tons of CO2 for every ton of PUR waste, making it a significant factor in the CO2 footprint.

45 % recycled regenerates

We have achieved unique results by recycling surplus materials from production and can now mold insulation materials with 45% regenerates. Regenerates in the form of cured PUR, where we reclaim production waste, thereby contributing to a more sustainable production process.
Previously, it has been associated with significant technical challenges to recycle rigid polyurethane foam in a way that preserves its key technical properties. Industrial recycling of PUR has been minimal, with success stories in the industry focusing on reusing 2-10% of production waste.

Our success in upcycling is the result of an intensive development process, where reducing waste and giving new life to materials have been the primary goals. We have worked with two methods in this process, both of which have yielded promising results. One technology is now ready to be implemented in production, delivering greener insulation. With the latest results, we have successfully molded products with a high degree of recycled content, while maintaining equivalent insulation values and material properties as conventionally molded PUR.

Green insulation saves space

By recycling excess PUR, we can significantly reduce our waste output and spare the environment from disposal burdens. The new production of greener insulation also opens doors to new markets. However, insulation with regenerates cannot be sold to the district heating industry due to standards for underground pipe systems, which do not permit recycled materials. This restriction benefits the plumbing industry, allowing regenerative insulation to be applied in areas where space constraints prevent traditional insulation. PUR insulation with regenerates is ideal for technical installations, offering highly efficient insulation that occupies far less space than traditional methods. Dan-iso’s insulation can therefore help meet requirements for heat loss and condensation in new construction and renovations.