On a straight path to becoming circular
At Ikano Industry Poland, we are moving at full speed to becoming fully circular by 2025, that is, to recycle as many mattresses as we produce.
In 2021, we worked to complete the construction of our new plant and warehouse for the production of Repoliol in Rogoźno in Poland. Simply explained, Repoliol is an Ikano-patented material made from recycled foam and the main building block for producing new foam. The new site is an EUR 6.3 million investment aimed to achieve zero waste while achieving 100% circularity in foam production.
In our current facilities in Rogoźno, we produce 1,000 tonnes of foam per year using the residue from the mattress production process. From the start-up of the new line, it will be possible to process an additional 2,000 tonnes/year, meaning we will be processing our residual foam at 100%. Production testing is set to start in early 2022.
The year 2021 also saw the development of the collaboration with Retour Matras. There are currently 4 plants in the Netherlands for the mechanical dismantling of post-consumer mattresses, 90% of each mattress can be reused in production. In the recycling process, fabrics are separated from the other part of the mattress, and the foam is processed mechanically: shredded, glued and pressed. The result is rebond foam, which can be used as soundproofing mats for floors .
Together with Retour Matras, we are also building a new Repoliol plant in the Netherlands with a planned start-up set for March/April 2022. The capacity will be around 900 tonnes of foam from post-consumer mattresses per year, which will produce around 2,200 tonnes of Repoliol. Glorious future!