ThaalChemy Innovations
Unlocking the Potential of
Polyurethane Foam Waste
Jan 2025
143, FF, 12th Main Road, Thirumudivakkam Admin@thaalinnovations.com
SIDCO IE, Chennai - 600 044
99401 08670
Introduction
Polyurethane foam is a remarkably versatile
material used in countless applications across
diverse industries. Its unique properties, such as
cushioning, insulation, and structural enhancement,
make it invaluable for improving comfort, energy
efficiency, and safety in both everyday products
and complex engineering solutions. This
widespread use underscores its significance in
modern manufacturing and technology
However, it accounts upto 10% of post-industrial
waste from all industries and generates several
environmental concerns.
Adhesives
7.3% Coatings
3.7%
Rigid foam Elastomers
7.3%
30.5%
Molded foam
13.4%
Flexible foam
37.8%
PU Foam market share by
application*
99401 08670; * Informations gathered from internet subject to validation
01
Problems of PU
Foam Producers
Thermoset polyurethane (PU) foam can not be remolded
Losing ~ 210000/ ton Upto 10 % wastage
of waste
01 02 in production
No established
Non recyclable and
chemical recyclers 03 04 Non- biodegradable
in India
Rebonding has issues of - Expensive disposal logistics
High density, performance 05 06 due to low density
issue, and high material costs
Environmental Hazardous to
land fill and incineration
07 08 High inventory cost
02
Admin@thaalinnovations.com
PU Foam India
Market Size
PU Waste:
PU Annual post - Industrial
waste (2023) 60900 tons,
₹60900 MT ₹870000 MT
worth INR 1339.8 Crores
Total PU production:
Annual PU Foam Production in
India (2023) 870000 tons,
2,32,14 Crores
Major Target Sectors
Insulation Packaging
Upholstery Mattress
foam foam
GII research report and Technavio market report predicts a CAGR of
7.05% for the Indian PU market, which translates to a potential size
exceeding 870,000 tons in 2022-23.
On an average generated 60,900 tons of post-industrial waste,
annually. This contains chemicals worth of 1339.8 Crores.
03
Admin@thaalinnovations.com
The Solution
Solving by converting waste PU foams into polyol with 80-90%
recovery efficiency through our patented technology
Disposal
Foam Producers PU Foam Waste for recycling
Factory process
Delivery starts
Chemical
Packaging Segregation
Processing
ProcessesShredding
at Thaal
Addressing the Pain Point -
Chemical Recycling of PU Foams into recycled raw material
Recycled Raw
Material 90%
Conversion recovery*
Process
Mixing 10-30%
PU Foam with virgin raw
material*
Rigid Polyurethane
Foam with 10-30%
recyclate
*Recycled matrial from our patented technology*
04
Admin@thaalinnovations.com
Our Services
Post Industrial Foam Post Consumer
Waste (PIW) Foam Waste (PCW)
Target Customers: Target Customers:
PU Foam Producers (Rigid and E-waste aggregators &
Flexible- Mattress, insulation, Municipal waste processing centers
automotive, sofa, textile, sports etc.)
1500 metric tons per annum production capacity in our service
converts PU foam waste into recycled raw material, a key ingredient
for high-density foam:
One ton of waste yields one ton of recycled raw material.
This recycled material blends with existing recycled raw material upto
30% for foam production.
Our chemical recycling maintains your original formulation's integrity
and properties.
Catalyst recovery ensures compliance with your application
requirements.
The resulting foam is also recyclable, creating a closed-loop system.
Optional waste segregation and shredding are available for an
additional fee.
Journey so far 2026
2025 International and National
market expansion
Customer Market Research,
validation, and new portfolio
2024 inclusion
Product development and
IPR creation, plant erection
15 metric /day, and
compliances
05
Admin@thaalinnovations.com
