Breakthrough Pilot Plant Will Recycle Rigid Foam Waste by 2028

A new pilot plant for recycling rigid foam waste is set to open in 2028. Developed by Covestro and Fraunhofer UMSICHT, the facility will use smart pyrolysis to turn insulation waste into high-purity aniline. This breakthrough could help meet growing demand for sustainable building materials across Europe.

The project stems from years of collaboration between Covestro and Fraunhofer UMSICHT, along with 23 other European research and industry partners. Their goal was to find a way to recycle PUR/PIR insulation foam, which is notoriously difficult to process due to its tightly bonded molecular structure. The new technology breaks down these bonds, recovering raw materials that would otherwise go to waste.

The pilot plant will handle 2,000 metric tons of foam waste annually. It will produce aniline with around 99% purity, suitable for making recycled MDI—a key chemical in insulation and refrigeration. The recycled MDI matches the quality of traditional versions but cuts carbon emissions by up to 40%. Testing on an industrial scale will allow the team to refine the process and supply material for further development. This comes as stricter EU regulations push for better recycling solutions, particularly for rigid foams used in energy-efficient buildings. The European market for these materials is expected to grow from 1.4 million metric tons in 2025 to 1.9 million by 2035.

The plant's opening in 2028 will provide a scalable way to recycle foam waste that was previously unrecyclable. By producing low-carbon MDI, the technology supports the shift toward greener construction and refrigeration. Industry experts see it as a critical step in meeting both regulatory demands and market needs.