Gábor Hangosi, from Purman, talks about turning industrial debris into stylish, sustainable furniture.
Industrial waste is one of the biggest challenges of modern society, and rigid polyurethane (PU) foam is a key contributor. Used in everything from warehouse insulation to refrigerated trucks, cold storage facilities, and sandwich panels, PU foam provides excellent thermal properties but presents a significant disposal problem. Once these structures reach the end of their life, the foam typically ends up in landfills, where it can take centuries to decompose. But what if we could transform this waste into something new and valuable? That’s where innovative recycling comes into play, turning industrial debris into stylish, sustainable furniture.
One groundbreaking approach to this recycling challenge focuses on mechanically breaking down rigid PU foam and giving it a second life as furniture. The upcycled foam is mainly applicable for furniture frames, making it an ideal solution for the furniture industry. This process begins with the demolition of old warehouses, cold storage units, or vehicles containing polyurethane insulation. Instead of sending the foam to waste, it is captured and recycled. Once the foam is collected, it’s shredded into small, reusable pieces. These pieces are then combined with lignin, a renewable resource often sourced from the by-products of the paper industry, along with other materials to create a strong, durable binder. Together, these components form a solid, sturdy material that can be moulded into furniture frames.
This blend of natural and synthetic binders ensures that the recycled material is not only robust but also versatile. By using lignin, along with other compounds, the recycling process minimizes the need for harmful synthetic adhesives while still producing a durable, long-lasting product. The end result? High-quality furniture that’s as tough as traditionally manufactured pieces but with a fraction of the environmental impact.
The materials used exhibit more favourable fire resistance compared to those commonly used in the furniture industry, enhancing the safety of the final products. Additionally, almost any shape can be cut and milled from the blocks, providing great flexibility for furniture designers and allowing for custom and innovative designs. Its density is higher than that of standard foam materials, ranging between 80-120 kg/m³, and it also has a high compressive strength, making it a durable and reliable choice for long-term use.
“The core idea was to develop a solution that’s both competitive and industrially scalable. A significant portion of rigid PU foams ends up in incinerators or landfills. This isn’t right because we’re talking about a material with great properties. It’s a waste to burn it, and most of the disposal methods aren’t sustainable. Even the newly developed chemical recycling methods are extremely energy-intensive, which limits their widespread use. In contrast, our method is very cost-effective, and, to be honest, it’s not just recycling—it’s upcycling, which makes us incredibly proud. We are targeting manufacturers, as upholstery or coating is required to finish the products. We are also seeking partners in manufacturers who are open to recycled furniture components to expand the use of this innovative material. The global patent is in progress.” – Gábor Hangosi
The transformation of polyurethane foam into furniture is more than just a recycling solution—it’s a prime example of upcycling, where waste materials are transformed into something better and more valuable. Instead of being discarded, industrial insulation materials are reborn as sleek, modern furniture pieces. Imagine sitting on a couch that once insulated a cold storage unit or lounging on a chair made from the walls of a refrigerated truck. It’s a tangible reminder that waste isn’t the end—it’s the beginning of something new.
The process of turning industrial rubble into furniture also brings significant environmental benefits. By recycling foam and using renewable binders, we reduce the demand for virgin materials like timber and steel, which are commonly used in furniture manufacturing. This shift helps preserve natural resources and reduces the environmental footprint of furniture production. Plus, using materials like lignin, a natural by-product, eliminates the need for harsh chemicals often found in traditional adhesives, making the process cleaner and safer for the environment.
As consumers become more conscious of sustainability, the demand for eco-friendly furniture continues to rise. People no longer just want beautiful and functional furniture—they want pieces that align with their values. The idea that a couch or table could be made from recycled insulation and foam not only appeals to those seeking sustainability but also adds a unique story to every piece. Each item carries with it a history of industrial use, now repurposed into something that plays a central role in daily life.
This innovative recycling method shows how we can reimagine the future of materials. A warehouse that once stored goods or a refrigerated truck that transported perishables now serves a completely different purpose, becoming part of someone’s home. And because the process retains the strength and integrity of the original foam, the furniture created is not only stylish but also highly durable.
The journey from warehouse to living room highlights the potential of circular design. Instead of viewing industrial waste as the end of a product’s life, this approach turns it into a new beginning. The use of advanced recycling techniques, combined with renewable binders, allows us to extend the life of materials that would otherwise be thrown away. It’s a powerful reminder that with the right technology, even the most unexpected materials can find a place in our homes.
In today’s world, sustainability is no longer just a trend—it’s a necessity. By incorporating recycled industrial foam into furniture design, we’re not only solving waste disposal problems but also contributing to a more sustainable future. The next time you sit on a stylish chair or relax on a comfortable couch, take a moment to think about where it came from. It could very well be that the furniture you’re enjoying was once a part of an industrial building or a cold storage facility.
The future of furniture is being built from the past. Demolish a warehouse, recycle the foam, and sit on the results—it’s that simple. This innovative process proves that with creativity and technology, even industrial waste can be transformed into something valuable and enduring.
