The sustainable collaboration and innovation between Indorama Ventures (IVL), Auping, and TWE Group demonstrate a certified cradle-to-cradle process for mattress components spanning nonwoven applications at Techtextil, Frankfurt, from the 21st to the 24th of June 2022.

The industrial collaboration between IVL Mullagh (Ireland), Auping, and TWE Group has resulted in a permanent, sustainable economic business model for manufacturers worldwide, using circular research and design. The use of safe raw materials in mattress production enables the materials to be readily dismantled at the end of use and reused as similar components or recycled into new raw materials of the same quality level, allowing for various textile applications.

Designed for disassembly to maximize the use of current resources, decrease carbon footprint, and support client objectives throughout the supply chain of their customers. This circular industry collaboration begins with design, as the mattress is built with only two different base materials: 100% PET polyester textiles and steel wire pocket springs connected with Niaga®, a non-toxic reversible adhesive that allows the mattress to be easily disassembled and recovered.

The connected and innovative circularity that serves to close the loop demonstrates IVL, Auping, and TWE's common ambition for a better future. Auping gathers, sorts, and separates the gathered textiles, which are subsequently processed, melted, and extruded to make polyester staple fiber at IVL Mullagh. TWE Group then converts these staple fibers into nonwovens for use in Auping's Evolve mattress, the world's first totally circular mattress. When a mattress is no longer in use, the material recovery process simply restarts.

Auping estimates that over 40 million mattresses are disposed of annually in Europe alone, the majority of which are incarnated. In the Netherlands, their take-back system guarantees that when their new mattress is delivered, the old mattress is removed and recycled, regardless of brand, guaranteeing existing resources are constantly optimized, diverted from waste, and maintained in use to establish a circular economy.

At Techtextil, IVL will present this closed-loop case study from their exhibition area in Hall 9.1, D05, to highlight their collaboration with Auping and TWE Group, where a shared sustainable vision, industrial inventiveness, and circular cooperation can be seen in action.

IVL Mullagh has been recycling more to have a less environmental effect for over 50 years. Their increasing technology allows them to recycle materials that others cannot. Together, they seek the most sustainable solutions to assist everybody to accomplish their sustainability objectives by collaborating with key stakeholders to decrease waste and incorporate recyclability and efficiency into goods and packaging.

As a global leader in PET recycling, IVL is reimagining chemistry to make the world a better place. The company is fully committed to innovate processes and materials to achieve a circular economy, as evidenced by its business practices and partnerships with industry to advance all of its business segments.

In the nonwovens, fibers, and textiles sector, IVL is collaborating with industry to fulfill increasingly complex market demands with collaborative and creative solutions for sustainable futures. IVL firms are collaborating with industry and each other to deliver the finest products and outcomes without compromising performance or the environment throughout all of their areas and polymers ranges. Techtextil 2022 will showcase innovations, and the IVL team is excited to learn how these developments will help clients achieve their sustainability goals.

Chris Kenneally, Executive President Fibers at IVL, said that they judge ourselves by the success of their client. They aspire to exceed customer expectations via professional cooperation, exceptional creativity, and a focus on quality. Their collaborative approach is consistent with their long-term sustainability goals, and they can deepen their commitment to increasing recycled content as they develop circularity in the industry together.

Geert Doorlag, Researcher on sustainability, sleep and ergonomics at Auping said that the change from linear to circular manufacturing demands patience and effort, but also a strong desire to make a difference. Partnerships are very important to them. They firmly believe in the value of knowledge sharing and attempting to transfer discoveries – such as in the field of sustainability – into useful solutions in collaboration with other parties.