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Mattress Component Recycling A study of the degree to which components arising from the deconstruction of used mattresses are sent for reuse or recycling.

Prepared by Oakdene Hollins for the National Bed Federation, February 2018

Mattress Component Recycling A study of the degree to which components arising from the deconstruction of used mattresses are sent for reuse or recycling. Written by: Steve Slater and Katie Baker Final check by: Katie Baker Approved by: Date: 14 February 2018 Contact: steve.slater@oakdenehollins.com Reference: NBF01 465.docx Disclaimer: This disclaimer, together with any limitations specified in the report, applies to use of this report. This report was prepared in accordance with the contracted scope of services for the specific purpose stated and subject to the applicable cost, time and other constraints. In preparing this report, Oakdene Hollins Ltd relied on (1) client/third party information which was not verified by Oakdene Hollins except to the extent required in the scope of services (and Oakdene Hollins does not accept responsibility for omissions or inaccuracies in the client/third party information) and (2) information taken at or under the particular times and conditions specified (and Oakdene Hollins does not accept responsibility for any subsequent changes). This report has been prepared solely for use by and is confidential to the client, and Oakdene Hollins accepts no responsibility for its use by other persons. This report is subject to copyright protection and the copyright owner reserves its rights. This report does not constitute legal advice.

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Contents 1 Executive summary ............................................................................................................ 2

1.1 Introduction ............................................................................................................... 2

1.2 Results of the study ................................................................................................... 2

1.3 Recommendations for further action........................................................................ 4

2 Mattress recycling and components ................................................................................. 5

3 Background ........................................................................................................................ 8

4 Survey of mattress recyclers .............................................................................................. 9

4.1 Identifying active organisations ................................................................................ 9

4.2 Survey questionnaire ................................................................................................. 9

4.3 Other research ........................................................................................................ 10

5 Study results .................................................................................................................... 11

5.1 Related findings ....................................................................................................... 11

5.2 Reuse and disposal of whole mattresses ................................................................ 12

5.3 End fates of components ........................................................................................ 12

5.4 Component recycling rates ..................................................................................... 14

6 Conclusions and recommendations ................................................................................ 17

6.1 Conclusions .............................................................................................................. 17

6.2 Recommendations for further action...................................................................... 19

Annex A : Long list of possible mattress recyclers ............................................................. 20

Annex B : Publicly available information on recyclers....................................................... 23

Annex C : Shortlist of recyclers contacted ......................................................................... 30

Annex D : Questionnaire .................................................................................................... 31

Annex E : Comments from recyclers taken from survey returns ...................................... 32

Contents amendment record This report has been amended and issued as follows:

Version Date Description Author Editor

FInal 14-02-18 Final report SS KB

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1 Executive summary

1.1 Introduction

The National Bed Federation (NBF) is supporting a nation-wide programme to increase the recycling of used mattresses and so reduce the number of mattresses being disposed of to landfill and incineration. On behalf of the NBF, Oakdene Hollins has reported on the number of whole mattress that are sent for recycling and researched how this can be improved. We now have a ‘recycling rate’ for whole mattresses, but we still do not know what percentage of the components and materials from deconstructed mattresses are actually sent for reuse or recycling, and how much goes to incineration or landfill.

This report covers the results of a study of mattress recyclers and waste management companies in the UK, the ultimate aim of which was to establish a reuse/recycling rate for each category of components.

The quantitative data sought from the mattress recycling sector were:

• How many mattresses do you process per year?

• Of these, how many are reused without further processing?

• How many are disposed to landfill or incineration, whole or shredded?

• What are the weights of each category of components recovered from the remaining mattresses following deconstruction?

• What are the end fates of these components?

By reconciling survey and interview returns with data from previous studies relating to whole mattress recovery, we expected to estimate a ‘recycling rate’ for each component category. The data would also serve to reconcile the annual quantities received by the recycling organisations with the quantities estimated to be recovered from the waste stream.

We also sought qualitative reports from the sector to provide an insight into the barriers and opportunities for increased mattress component reuse and recycling.

1.2 Results of the study

• Responsible recyclers There are just eight major mattress recyclers in the UK. Others, identified in earlier reports, have gone out of business - presumably because they failed to achieve a financial return on their operations.

• Willingness to co-operate Some operators refused to give us any quantified data on the basis that it is commercially confidential. Others were eager to share information on the basis that proliferation of ideas would benefit the sector as a whole, thereby improving the market for all.

• Reuse of whole mattresses and mattress components Whole mattresses, especially of retail returns which are seen as ‘nearly new’, are being resold for reuse. Many clean, undamaged components extracted during the deconstruction process are also being reused in the manufacture of new mattresses.

• Deconstruction methods There is no fully automated machine that can cleanly deconstruct the wide variety of mattress types and sizes found in the waste stream. Some recyclers have devised part-

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mechanical systems, although these damage many of the components in the process. Though it is successfully carried out, in full personal protective equipment, some operators regard manual deconstruction as unsafe.

• Maximising component value Each recycler works to maximise the value of the extracted components through innovative processing. Recyclers that operate as part of a wider waste / resource management group, or have access to other waste materials that can be bulked up and blended with those recovered from mattress recycling, are at a clear advantage. Where no local opportunities are found, components and materials are exported for further processing. Economies of scale are also an important factor – the greater the throughput, the more outlet options are available for sale of the components.

• Finding markets There is no overall pattern of end fates for the components, either by processing route or by quantity, because markets for extracted materials are often dictated by local circumstances. The main requirement is to minimise transport costs for the components, which are mainly high bulk and low value. Recyclers in Ireland, for instance, have to ship many of the extracted components to Britain for processing. There is a clear benefit from being close to large urban centres, and to a commercial dockyard, for low cost exporting. Other examples of the benefits of local facilities include recyclers who are close to a bed remanufacturing company, a steel processor, and a textile recycler.

• Restricted markets Some recyclers reported that restrictions are placed upon them through the contracts they hold with their ‘suppliers’, i.e. the retailers and local authorities, preventing them from accessing certain outlets for whole mattresses or for components. Again, this adds to the variety of end fates between the major recyclers.

• Mattress recycling rates Even with a lack of data from some quarters, our study of recyclers found significantly greater numbers of mattresses being recovered for recycling than we have previously reported from estimates based on top-level data. We estimate that some 1.4 million units per year are currently being put through the major recyclers, and that the numbers are increasing. This compares with a figure of just below 1.0 million that we previously reported based on 2015 data.

• Component recycling rates For many of the reasons noted above, it has not been possible to accurately quantify current component recycling rates for used mattresses in the UK. However, we are clear that the major UK mattress recyclers achieve nearly 100% avoidance of landfill of extracted components. Instead, components are either reused in new mattresses or in other products (particularly upholstery), recycled for use in new and unrelated products, or processed into refuse derived fuel (RDF) for energy recovery. As noted above, the mix between these options varies by component category and from site to site. Clearly it is desirable to reduce the dependence on energy from waste. And though reuse is a preferred option in the waste hierarchy, it is important to review reuse in new mattresses and other upholstery products, for reasons of both commerce and safety.

We have attempted to estimate, from the limited data, current component end use rates. These are shown in detail in Table 3 on page 9. The headline figures are: springs are 96% recycled, foam is 85% recycled, and more than 50% of woven textiles are sent for energy recovery, probably because they are often contaminated or damp.

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1.3 Recommendations for further action

Our recommendations are to promote co-operation and dissemination of best practice, to create a regulatory environment to facilitate recycling, and to nudge the economics in favour of recyclers so that the whole sector can grow:

• Set up a ‘Responsible Recyclers’ group comprising the major, compliant operators. This would facilitate real data gathering, target and improvement setting, and could be the forerunner of a professional stewardship programme for the member organisations which would, in turn, become the preferred outlets for used mattresses.

• Lobby for regulation, such as a ban on whole and shredded mattresses to landfill. Apart from being the intuitive preferred option, this would drive up the gate fees that could be charged by the recycler, thereby improving the financial return and long-term stability of the sector.

• Consider setting a disposal charge on the purchase of new mattresses which would be used to fund investment in recycling through a formal producer responsibility scheme. Funds raised could be used to support investment in the recycling sector.

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2 Mattress recycling and components

The NBF estimates that the annual sales of replacement mattress in the UK in 2017 was 5.3 million units. It remains the case that most of the used mattresses displaced are landfilled rather than being recovered for recycling. The fact that a single, whole mattress takes up approximately ten times the landfill void space on a weight for weight basis, when compared to other wastes, is a factor that could well deter landfill operators from accepting them in the future. Some waste management companies continue to shred the mattresses before landfilling, but this is an expensive option.

When further considering the activities of the mainstream waste and resource management industry, and through correspondence with the Environmental Services Association (ESA), which represents the majority of the players in this sector, we have been told that none of the major waste operators are currently recycling mattresses. Clearly they play a significant role in the collection, storage and transportation of used mattresses but, since this report only concerns the process of recycling, we did not need to survey the wider waste management sector.

The supply chain for mattress recycling is set out in Figure 1.

Figure 1: Mattress recovery and recycling process

In Figure 2 we summarise the types of mattress currently being recovered, and their component parts.

Sourcing, collection

and transport

De-construction

Checking and

unloading

Component separation

and processing

Distribution of materials

to end markets

Landfill or Energy from

Waste

Reuse/Remanufacture

Export

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Figure 2: Recycling of mattress components

In this report we use the term ‘components’ to cover all of the constituent parts of the mattress. We were given the following categories for analysis:

1. Springs & all other metal components (e.g. staples and clips). Springs are either ‘Bonnell coil’ or pocket and are handled differently

2. Ticking fabrics (Textiles (natural or synthetic) 3. Foam pads 4. Synthetic fillings, (e.g. polyester, polyurethane, gel pads, pocket spring wrapping) 5. Natural fillings - woven, (e.g. wools, cottons and blends) 6. Natural fillings – nonwoven, (e.g. wools, cottons and blends) 7. (Fillings, i.e. thicker comfort layers, are either synthetic – mainly polyester, or natural –

mainly nonwoven felt or ‘shoddy’ but also coir) 8. Other materials, (e.g. labels, trims, etc.).

In practice, the recyclers did not differentiate ticking fabrics from other sheet textiles and used terms such as ‘shoddy or ‘felt’ to mean nonwoven fillings. Also, categories appeared to be based more on the end markets/fates for the components than on their base material. We have therefore modified the above categories to the following:

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1. Bonnell coil springs

2. Pocket springs

3. Woven textiles

4. Foam pads

5. Synthetic filling – polyester

6. Nonwoven/shoddy felt

7. Natural filling – coir 8. Other materials (e.g. plastic film, rigid plastics, wood)

It was generally agreed that, if standard reporting of recycling across the sector is to be created in the future, then these categories should be agreed and be more clearly defined.

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3 Background

As noted above, Oakdene Hollins has studied the UK mattress recycling market on behalf of the NBF over a number of years. Much of the data obtained during this time were received from mattress manufacturers and retailers, local authorities and from public sector databases, such as WasteDataFlow and Eurostat. It was not possible to obtain significant quantified information from the recycling organisations or from those waste management companies that handle mattresses.

Whilst the data gleaned from earlier studies were sufficient to gain an understanding of the rate at which used mattresses are being recovered from the waste stream for recycling, they could not be used to establish what happens to them and to their components after they have been collected. For this, we need good information from the recycling companies themselves, and this continues to be a problem for the reasons set out below.

Often, where we have identified a recycler organisation from internet searches or from industry contacts, we either could not contact them because they had ceased trading or, where we did gain contact, they were reluctant to respond to our questions on the grounds of confidentiality.

It is clear that the economics of mattress recycling remains difficult. The cost of transport, handling, and deconstruction of the wide range of types and sizes of mattresses remains high, whilst the markets for all components, apart from steel springs, are limited. Entrants to the sector may be attracted by charges made for collection, but find that they have difficulty disposing of the components.

In 2014 we identified 18 recycling companies in the UK which were listed as dealing in used mattresses. This figure was down to 13 when the figures were re-visited in 2016. In the event, only eight of these are currently trading in significant quantities in the UK and one further organisation in the Republic of Ireland. Estimates of small, local operations in the UK, range from 12 to 20 in number.

Not all mattresses that are recovered from the waste stream are sent for recycling. They may be in sufficiently good condition to go straight for reuse. Indeed, anecdotal evidence suggests that this route is increasing rapidly on the back of growing internet and mail order sales, where returns schemes are in operation which allow the customer to trial the mattress for a few days or weeks. In these cases the returned items are shipped to third sector organisations for resale. Some remanufacturing or refurbishing of lower quality recovered mattresses takes place, although this is not seen as being a significant disposal route. At the other end of the quality spectrum, mattresses that have been collected for recycling, but which are badly soiled or damaged in some way, will be sent to landfill of incineration for energy recovery. However, it remains that the clear majority of mattresses that are recovered from the waste stream are in fact sent for recycling, i.e. deconstruction into their component parts which are then sold for reuse or recycling into new products. Whilst deconstruction is happening in the UK primarily, many mattresses are exported for deconstruction in countries where labour cost are lower and, it is understood, health and safety restrictions are less onerous.

It is the mattress components that are the main subject of this report.

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4 Survey of mattress recyclers

4.1 Identifying active organisations

The companies that were known to currently be recycling mattresses, or to have been involved in recycling mattresses in the recent past, were discovered from the following sources:

1. Previous surveys 2. Companies known to be in discussions with, or being targeted by, the NBF and the

Textile Recycling Association (TRA) as founder members of a professional recyclers group, and

3. An internet search using terms such as recycle[-r, -ing], mattress[-es], removal.

From the long list in Annex A, for which publicly available information on them is shown in Annex B, a shortlist of companies that are actively recycling mattresses was drawn up for us to contact to take part in the survey. These organisations are shown in Annex C.

Note: Whilst not strictly within the scope of this study, we have included one mattress recycler in the Republic of Ireland, on the argument that some statistical information from these companies might be relevant in establishing a component recycling rate.

4.2 Survey questionnaire

Based on a study carried out for Zero Waste Scotland in 2010, the average composition by weight of mattresses were as shown in Table 1. One of the aims of the survey was to confirm this mix of materials, or to see how it might have changed in recent years.

Table 1: Average composition of mattresses sold in the UK, 2010

Material Average mattress composition (%)

Steel 29%

PUR and latex foam 28%

Cotton, non-woven, felt 22%

Natural fibres (e.g. coir, sisal, jute) 7%

Cotton & wool, woven 10%

Polyester 4%

Total 100%

A Business Case for Mattress Recycling in Scotland, Zero Waste Scotland, 2012

A short survey was devised and sent to all of the identified organisations. This survey asked a number of questions, summarised in Annex D. Whilst it was not expected that all questions would be answered by all respondents, the survey was an attempt to gather the key component recycling data and to provide a good level of confidence that the figures were statistically sound.

The quantitative data sought from the mattress recycling sector were:

• How many mattresses do you process per year?

• Of these, how many are reused without further processing?

• How many are disposed to landfill or incineration without further processing?

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• What are the weights of each category of components recovered from the remaining mattresses following deconstruction?

• What are the end fates of these components? The possible ‘end fates’ are:

• Reuse, e.g. in new mattresses or other products

• Recycling

• Incineration, e.g. as refuse derived fuel (RDF), or without energy recovery

• Landfill

• Export – where the final fate of the components is unknown.

Questionnaires were sent to all the organisations listed in the shortlist (Annex C). We received responses from just six organisations in the UK and from one in the Republic of Ireland. No other significant formal responses were received, but supporting and additional data were gathered from follow-up phone calls and from site visits.

The survey results are summarised in Table 2 on page 15. The data focusses on the end fates of the components.

4.3 Other research

In parallel to the survey questionnaire we held telephone interviews with a number of the recycling organisations listed, to add further information and clarification to their responses, with the Textile Recycling Association, the Environmental Services Association and with two key waste management organisations. We also visited two of the major recycling plants for first-hand knowledge of the recycling operation.

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5 Study results

5.1 Related findings

The initial finding, which was confirmed by follow-up interviews and other anecdotal evidence, is that there are only eight mattress recyclers in the UK that take in significant quantities of used mattresses and that have relatively stable operations. A number of these reported the existence of ‘rogue operators’ who have collected used mattresses at a fee and then, either for economic reasons or through criminal activities, have failed to process them. It was reported that used mattresses are stockpiled in five warehouses across the country, without processing, and left to the responsibility of the landlord to dispose. The second key issue was that some of the eight UK recyclers refused to disclose much of the requested data, claiming commercial confidentiality and non-disclosure agreements with clients.

Although some information was gleaned from the follow-up calls and site visits, there remain significant gaps in the data received. Furthermore, it is clear from the responses received that the other organisations do not all retain (or did not disclose) accurate records, particularly for the weights of components shipped. Much of the data was clearly rounded or estimated. This issue may have been compounded by the problem of categorisation of each recovered material, as discussed earlier. However, it is also clear that there is little stability in the various supply chains, with the recyclers continually looking for new outlets and taking spot deals for the ‘more difficult’ materials, all of which contributes to a constantly shifting picture.

From the initial question asking for numbers of mattresses received, and by approximations for those contacts who did not respond, we estimate that these eight UK companies account for the recovery of approximately 1.4 million units per annum. This is somewhat greater than the estimated 0.95 million mattresses that were recovered from the waste stream in 2015, taken from our earlier studies and based on data from Local Authorities and elsewhere. It is clear that this represents a major increase in activity in the last two to three years. This is confirmed by most of our contacts, who reported that there has indeed been a significant growth in mattress recycling in the last year or two. The reasons for this are clear:

• Shortage of landfill. Local Authorities are increasingly turning to the recyclers to take mattresses where landfill space is in short supply or where the landfill operators refuse to receive them, arguing that they take up too much void space or that they represent hazardous waste.

• Economic reasons. With gross landfill costs at up to £130 per tonne, the disposal of each mattress would cost c.£3.25 plus transport. If a recycler which is situated within reasonable distance of the source, and can collect at c.£4.00 each, this is an attractive and more sustainable alternative to the local authorities, waste management companies and commercial collectors.

• Mattress returns. There is a growth in 60/120 day ‘Comfort Trials’, in which the retailer offers to take back a used mattress if the customer is not happy with it, either offering a refund or an upgrade to a better quality item. We saw large numbers of almost new and very clean mattresses in the recycling stream, some even in their original wrapping, as witness to this fact.

• Stockpiles. Response by the responsible recyclers to requests from the Environment Agency and from private landlords to clear tens of thousands of illegally stockpiled mattresses.

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We found that the mix of mattress types and sizes in the waste stream, and therefore the average component composition (see Table 1), has remained sensibly constant in recent years. Also, from survey data received, and from follow-up interviews with recyclers that carry out mass balance studies, we returned a range of figures for the weight of the ‘average’ mattress of between 22kg and 28kg. These figures give a degree of confidence that the figure of 25kg per mattress, used in the earlier surveys to establish a mattress recycling rate, is reasonably accurate.

There is a possible trend towards pocket springs, away from coil springs, but this does not affect the quantity of steel in the extracted components. The suggested trend towards new foam mattresses has not yet caused a significant growth in the amount of polyurethane foam in the waste stream, due to the time lag of eight years or more between the purchase and disposal of new mattresses. This situation may be changing now, however, as a result of the trend to offer ‘Comfort Trials’, discussed elsewhere in this report, which is causing a short-term surge in foam mattresses being sent for recycling.

5.2 Reuse and disposal of whole mattresses

Where the source of used mattresses is, say, from a retailer take-back scheme, their condition is considerably higher than those recovered from Local Authority operated household waste and recycling centres (HWRCs) where dirt, dampness and bulk handling have all contributed to their deterioration.

We saw an increasing trend for mattresses recovered from the waste stream to be of such good quality that they can be reused without further treatment. This trend is driven to a large extent by the recent offering by some retailers of a 60/120 day ‘Comfort Trial’, as noted above. One recycler reported that some 40% of all mattresses received in recent months were from this source. To maximise returns on such loads, recyclers carry out a sorting operation on receipt so that they can single these items out for shipping to, say, a local charity, for resale. It is not clear if this practice is sustainable and we note that (whilst it may not be related) the retailer Warren Evans - who argued that they made a profit from the scheme because customers invariably traded up following the trial - has now gone into administration.

At the opposite end of the use spectrum are those mattresses recovered from the waste stream that are either heavily contaminated or very wet, and not suitable for deconstruction. Some recyclers refuse to take such items, meaning that these have to be landfilled whole or be shredded for landfilling. However, these activities appear to be reducing for the reasons outlined above.

5.3 End fates of components

All other mattresses recovered from the waste stream are deconstructed for their component parts. Deconstruction is mostly in the UK, but significant quantities are baled, to reduce bulk, and exported whole for deconstruction overseas. (In these instances we make the assumption that the end fates for components are similar to those in the UK.) End fates of the components can be divided into:

• Reuse – either in new mattresses or other products.

• Recycling – into secondary materials for new products.

• Baled as refuse derived fuel (RDF) – or sent directly for incineration with energy recovery.

• Disposal to landfill.

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Some of the components were reported to be exported, but for similar processing and end applications. In these cases we have assumed that, whether the outlet for the components is based in the UK or overseas is not relevant to the overall picture.

Notwithstanding the paucity of the data received, it is possible to identify some clear trends for each component category:

1. Bonnell coil springs. All recyclers confirmed that these steel springs can be 100% recycled. Whilst the interlocked structure of the traditional coil spring can cause difficulty in the smelting process, if shipped without further processing, good quality baling can overcome this. The format of the shipment, however, may affect the price paid by the processor.

2. Pocket springs. Again, the steel from these springs can be 100% recycled. Whilst these smaller, separated springs, are easier to handle than the large coil springs, is clearly not economic for the mattress recycler to manually separate them out from their synthetic textile pockets. Where the pocket springs are shredded, magnets are used to separate out the metal, but the format of the shredded steel springs means that it retains significant amounts of textile. Where the polyester pockets are removed they may be mixed with the main polyester fraction for similar end uses. Baling is also a possibility and, whilst textile remains in the baled steel, the problem for the metal reprocessor can be reduced by mixing with other steel wastes. Whilst such innovative treatments of these items by the recyclers have been shown to yield a material that can demand good prices from metal recyclers, higher value could be obtained for ‘clean’ steel springs. Here it is noted that the synthetic textile pockets can be 100% burned off, yielding clean, high value steel. This practice is not permitted in the UK but is reported to be acceptable in some of the countries taking whole mattresses, making it easier for those countries to obtain higher value from the steel.

3. Woven textiles.

We found very little reuse applications for the various woven textiles that are recovered from the deconstruction process. The main issue here is that they are a mix of material types and are often dirty, contaminated or damp. In these instances, they are mainly baled and sent for incineration with energy recovery. Some clean woven textiles are sent to the recycling trade for either cutting into wiper rags or shredded to produce non-woven textiles. There was also some evidence of soiled materials being sent to community/prison washing facilities to clean them up prior to cutting into wipers. We did not receive sufficient data here to quantify the amounts that are currently going to these two routes, i.e. incineration or recycling.

4. Foam pads.

All of the (mainly polyurethane) foam can be reused or recycled, as follows:

• Reused in new mattresses. We found a number of clean foam mattress pads that are being sent to remanufacturing companies who fit them with new textile covers and resell them as new mattresses. If there is some soiling or damage, the mattress can be trimmed down to remanufacture into smaller mattress sizes.

• Reused in e.g. pet bedding. Off-cuts have a wider reuse application in furniture upholstery.

• Recycled foam. Sent for processing into recycled foam – with a wide variety of uses in upholstery, carpet underlay, insulation, etc. Also, we understand that

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some foam is granulated and used as a soil amelioration material and for water retention in dry regions.

Synthetic filling – polyester. Clean polyester fibre is all sold for reuse without further processing into new products, including mattress manufacture, and even partly-soiled fibre can be recycled for a wide variety of products.

5. Non-woven/shoddy felt. We found that the greatest use of non-wovens is for equestrian maneges. Here it is chopped into granules and spread on the horse training/exercise ground as an alternative to, say, rubber granules from recycled tyres. The surfaces have to be refreshed on a regular basis.

6. Natural filling – coir. The main use of this material is in the horticultural sector where it is used for e.g. hanging baskets. As it is often an inner layer and therefore very dry, it can be added to the wet fraction to increase its suitability as a fuel.

7. Other materials. The above summary covers over 95% of the components recovered during the mattress deconstruction process. Where other materials, such as wood, rigid plastics, film packaging, etc. are accumulated, these are largely sent for incineration with energy recovery.

5.4 Component recycling rates

As previously noted, it is not possible to accurately quantify current component recycling rates for used mattresses in the UK. This would require further work, extending to gaining formal returns from overseas recycling companies and, importantly, consent from all of the major UK recyclers to co-operate in a data recovery programme. The problem here is that, with the gate fees that they can charge for taking in mattresses being often limited by landfill rates, achieving a secure financial return in a regulated waste market requires an aggressive and innovative approach to processing and marketing the components. This requires hard work and commitment, and some chief executives/owners do not wish to disclose any of this information to third parties, where it might be picked up and acted upon by a competitor. Another reason cited for not given relevant data is the existence of non-disclosure agreements with their suppliers, notably the bed retailers.

Notwithstanding this issue, it is clear from our study that, whilst much use is made of the RDF/EfW option, especially for soiled materials, no components need to be sent to landfill.

The debate then moves on to how much of each component type is being, and should be reused, recycled, or incinerated with energy recovery.

Table 2 shows the data that we have received during the study. It shows a summary of the returns from the major UK recyclers and from the one in the Republic of Ireland. Due to the small data source population we have aggregated the mattress quantities (which would have otherwise given an indication of which data is from which source), and have anonymised the individual entries. The data confirm that the fates of each component type varies widely from company to company.

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Table 2: Summary of results showing end fates of components Mattress

Quantities Ref Components for

Reuse Components for

Recycling Components for

RDF & EfW Components

Landfilled Notes

Estimated 1,400,000 Mattresses annually based on questionnaire returns, follow-up interviews and web data

1 Nil 100% All springs 100% All other Nil 100% mattresses from Local Authorities. Hard to find markets for all fabrics except ‘poly’ Markets for components has been poor but some interest is beginning in textiles. Number of mattresses is increasing. Market for steel has been static.

2 30% Springs 40% Nonwovens 40% Foam 70% Polyester

70% Springs 40% Foam

60% Nonwovens 20% Foam 30% Polyester 100% Other textiles

Nil 30% mattresses from retailers; 50% from Local Authorities, in any condition. 40% ‘comfort trial’ mattresses in [Christmas period]; this is expected to increase. 80% of outputs go to local markets.

3 100% Textiles Data are “commercially sensitive”

4 Nil 100% Springs 100% All other

Nil Nil Textile information not provided separately for woven/non-woven.

5 Nil 100% Springs 100% Foam 100% Polyester

100% All other

Nil

6 75% Nonwovens 55% Polyester

100% Springs 100% Foam 65% Wovens 22% Polyester

7% Wovens

Nil NB: Returned data did not total 100%. 80% mattresses from Local Authorities End use data apply to components of deconstructed mattresses only.

7 Would not supply data

8 Nil 100% Springs 45% All other

55% All other

Nil 75% mattresses from retailers, manufacturers and contract; 15% from Local Authorities. Average mattress weight 25kg.

9 Nil 100% Springs 100% Polyester 100% Foam ‘Most’ Nonwoven

100% wet outer fabric

Nil Nearly 100% ‘end-of-life’ mattresses from LAs. Textile is 2/3 of mattress by weight. 100% of clean dry materials are recycled, but that isn’t 100% of the mattress. Tried (and failed) to give shoddy to homeless charities and furniture removers for reuse.

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We have attempted to estimate, from the limited data, current component end use rates. These are presented in Table 3 below:

Table 3: Estimated component end use rates

Component category Reuse Recycle RDF/EfW

Springs 4% 96% 0

Nonwovens 52% 0 48%

Foam 5% 85% 10%

Polyester 43% 31% 26%

Woven textiles 0 42% 58%

Other n/a n/a n/a

These figures should be treated with caution but, from our observations during the research conducted for the study, they appear realistic.

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6 Conclusions and recommendations

6.1 Conclusions

The following are our headline findings:

Responsible recyclers

There are just eight significant, and apparently compliant, mattress recyclers in the UK. A number of smaller collectors process small quantities but, historically, there have also been a number of ‘rogue operators’, who were clearly non-compliant. Others, identified in earlier reports, have gone out of business, presumably because they failed to achieve a positive financial return on their operations.

Willingness to co-operate

Some operators refused to give us any quantified data on the basis that it is commercially confidential. Others, however, were eager to share information on the basis that proliferation of ideas would benefit the sector as a whole thereby improving the market for all.

Reuse of whole mattresses and mattress components

Considerable resale for reuse of whole mattresses is occurring, especially with retail returns which are seen as ‘nearly new’. Also, sale of components for reuse in new mattresses is also occurring - again, where components such as spring sets and foam pads can be recovered in an ‘as new’ condition for re-manufacturing.

Deconstruction methods

Manual deconstruction of mattresses using knives is seen by some operators as unsafe. Where this is carried out, however, full personal protective equipment (PPE) is used to ensure safe operation, and this appears to be successful. There is no fully automated machine that can cleanly deconstruct the wide variety of mattress types and sizes found in the waste stream. (Anecdotally, we were told that the machine that has been built in The Netherlands for this purpose only handles foam mattresses – and its efficiency is doubtful). Some recyclers have devised part-mechanical systems, although these damage some of the components, particularly foam pads, in the process. The alternative for other recyclers is to simply export the mattresses whole for deconstruction overseas.

Maximising component value

Each recycler is working hard to devise innovative component treatments in order to maximise their value. Baling, shredding and textile extraction, are processing options being tried. Here, mattress recyclers that operate as part of a wider waste and resource management group, have access to other waste materials that can be blended with those recovered from the mattress operation, sometimes to add value. Where limited by the extent of the processing facilities, and restricted by waste legislation, many materials are being exported for further processing, particularly to Europe and to South East Asia. Economies of scale are also a factor – the greater the volume of components being recovered, the greater the interest from secondary material processors.

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Finding markets

There is no overall pattern of end fates for the components, either by processing route or by quantity, because markets for extracted materials are often dictated by local circumstances. The main requirement is to minimise transport costs for the components, which are mainly high bulk and low value. Recyclers in Ireland, for instance, have to ship many of the extracted components to mainland Britain for processing. There is a clear benefit from being close to large urban centres, and to a commercial dockyard, for low cost exporting. Other examples of the benefits of local facilities include recyclers who are close to a bed remanufacturing company, a steel processor, and a textile recycler.

Restricted markets

Some recyclers reported that restrictions are placed upon them through the contracts they hold with their ‘suppliers’, i.e. the retailers and local authorities, preventing them from accessing certain outlets for whole mattresses or for components. Again, this adds to the variety of end fates between the major recyclers.

Mattress recycling rates

Even with a lack of data from some quarters, our study of recyclers found significantly greater numbers of mattresses being recovered for recycling than we have previously reported from estimates based on top-level data. We estimate that some 1.4 million units per year are currently being put through the major recyclers, and that the numbers are increasing. This compares with a figure of just below 1.0 million that we reported based on 2015 data.

Component recycling rates

For many of the reasons noted above, it has not been possible to accurately quantify current component recycling rates for used mattresses in the UK. We believe that, amongst the major UK mattress recyclers, avoidance of landfill of recovered components is currently 100% and should remain the target. All components are, either:

• Reused in new mattresses,

• Reused in other products, particularly upholstery,

• Recycled for use in new and unrelated products, or

• Processed into refuse derived fuel (RDF) for incineration with energy recovery.

The mix between these options varies by component category as detailed in the body of the report. Steel, for instance, can be 100% recycled and is can demand high prices, whereas outlets for woven textiles are limited and are often disposed of at a cost.

Clearly it is desirable to reduce the dependence on energy from waste. Also, whilst being a preferred option in the waste hierarchy, it is important to address the issue of reuse of some components in new mattresses and other upholstery products, both from a commercial point of view and with regard to compliance with furniture safety regulations.

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6.2 Recommendations for further action

Co-operation

Set up a ‘Responsible Recyclers’ group comprising the major, compliant operators. This would facilitate real data gathering, target and improvement setting, and could be the forerunner of a professional stewardship programme for the member organisations which would, in turn, become the preferred outlets for used mattresses. (It is noted that the NBF is already taking action in this regard, in conjunction with the Textile Recycling Association). Here, lessons may be drawn from the success, over many years, of the Responsible Recyclers group for used tyres, operated by the Tyre Recovery Association and the tyre manufacturers and retailers. NB: If there is to be standard reporting of recycling across the sector, then the component categories need to be agreed and be more clearly defined.

Encouragement

Lobby for regulation, such as a ban on whole and shredded mattresses to landfill. Apart from being the intuitive preferred option, this would drive up the gate fees that could be charged by the recycler, thereby improving the financial return and long-term stability of the sector. However, a ban would need to be carefully managed to avoid the unintended consequence of fly tipping.

Remuneration

Consider setting a disposal charge on the purchase of new mattresses which would be used to fund investment in recycling through a formal producer responsibility scheme. Again, funds raised could be used to support investment in the recycling sector.

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Annex A : Long list of possible mattress recyclers

Companies that were known to currently be recycling mattresses, or to have been involved in recycling mattresses in the recent past, were discovered from the following sources:

• Previous surveys

• Companies known to be in discussions with, or being targeted by, the NBF and the Textile Recycling Association (TRA) as founder members of a professional recyclers group, and

• An internet search using terms such as recycle[-r, -ing], mattress[-es], removal.

From the list, a shortlist of companies that are actively recycling mattresses was drawn up for us to contact to take part in the survey. These organisations are shown in Table 1. Note: Whilst not strictly within the scope of this study, we have included mattress recyclers in the Republic of Ireland, on the argument that some statistical information from these companies might be relevant in establishing a component recycling rate.

Table 4: Search results for mattress recycling organisations – UK and Ireland

Company name Address Telephone Website

Mattress Recycle Ltd Icknield Way Farm, Tring Rd, Eaton Bray, Dunstable LU6 2JX

01582 674626 http://www.ecorubbishclearance.co.uk/Pages/Mattress_Disposal_London.aspx

Eco Mattress recycling Ireland

Unit 133A, Slaney Rd, Dublin Industrial Estate, Dublin, D11 E6XC

+353 1 860 3619 http://ecomattressrecyclingireland.com/

The Furniture Recycling Group

Victoria Works, Blackburn BB2 4DD

01254 205155

0800 050 9867

http://www.tfrgroup.co.uk/

Space Waye Recycling Centre

North Feltham Trading Estate, Pier Road, off Faggs Road, Feltham, TW14 0TH

020 8890 0917 https://www.hounslow.gov.uk/info/20017/space_waye_re-use_and_recycling_centre/

Collect & Recycle Ltd = CollectYourOldBed.com ?

6 Waystead Close, Kingsmead, Northwich, Cheshire, CW9 8NN

01606 45830

AAT RECYCLING LIMITED -

Unit 8, Prees Industrial Estate, Shrewsbury Rd, Prees, Whitchurch SY13 2DJ

01948 840251 http://www.aatrecycling.com/

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Company name Address Telephone Website

Recycle For Calderdale

22 Waterhouse St, Halifax HX1 1UQ

01422 288002 https://www.calderdale.gov.uk/v2/residents/environment-planning-and-building/waste-and-recycling/recycling/a-z

Farthinghoe Recycling and Reuse Centre -

A422, Brackley NN13 5PB

01295 713782 https://www.southnorthants.gov.uk/info/10/waste-and-recycling/10/farthinghoe-recycling-and-reuse-centre/2

Recycle Me Free - 6 Dragon Rd, Harrogate HG1 5DF

07940 226028 http://www.recyclemefree.co.uk/

The Furniture Recycling Project -

12-14, Grosvenor House, Station Rd, Gloucester GL1 1SZ

01452 302303 http://www.frpglos.org.uk/

Hunters Lane Waste Recycling Centre -

Hunters Ln, Rugby CV21 1EA

http://www.warwickshire.gov.uk/recyclinghunterslane

Kingston Community Furniture –

1 - 3, Dollary Court, Dollary Parade, Kingston Rd, Kingston upon Thames KT1 3PD

020 8942 5500 http://www.kingstoncommunityfurniture.org/

Bulky Waste HQ - Recycling Lives Centre, Essex Street, Preston PR1 1QE

01772 566556 https://www.furnituredonationnetwork.org/

Eco Rubbish Clearance

Unit A7 Staples Corner Business Park, 1000 North Circular Rd, London, NW2 6LU

020 8450 4567 http://www.ecorubbishclearance.co.uk/Pages/default.aspx

We Clear Junk Unit 5 Bridge Park, Harrow Road, London, NW10 0RG

020 8961 2861 https://www.weclearjunk.com/

V&W Recycling Dundalk Recycling Centre, Newry Rd, Lisdoo, Dundalk, Co. Louth, Ireland

+353 42 932 9200 http://www.vandwrecycling.ie/

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Company name Address Telephone Website

Furniture Donation Network HQ

1-2 Essex St, Preston PR1 1QE

01772 566557 https://www.furnituredonationnetwork.org/

Viridor Recycling Brighton Rd, Shoreham BN43 6RJ

01273 454081 http://www.recycleforwestsussex.org/recycling-guidance/?l=M

Wastesavers Reuse Centre

Phoenix Park, Newport NP19 0LW

01633 216855 http://wastesavers.co.uk/at-home/z-recycling-newport/

Airsprung Beds Factory Shop

Canal Road Industrial Estate, Canal Rd, Trowbridge BA14 8RQ

01225 754411 https://airsprungfactoryshop.co.uk/collect-and-recycle

CAD RECYCLING LTD Calor House;Bron Y Nant, Colwyn Bay LL28 4YL

01492 545954 http://www.mikehoganskiphire.co.uk/

Amgen Bryn Pica Bryn Pica, Llwydcoed, Aberdare CF44 0BX

01685 372909 http://www.amgen-cymru.com/

Circom 3 Telford Rd, Exhall, Coventry CV7 9ES

02476 100 189 http://circom.co.uk/

MattUK Deptford Recycling Centre, Landsmann Way, Deptford, SE14 5RS

0800 111 4443 http://www.matt-uk.co.uk/

USEL 182-188 Cambrai Street, Belfast, BT13 3JH

028 9035 6600 https://www.usel.co.uk/

Hamilton Smeaton Recycling Centre, Carberry, Mussleburgh, Edinburgh EH21 8PZ

0131 665 2173 http://www.hamiltonwaste.com/

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Annex B : Publicly available information on recyclers

Many of the companies in Annex A give useful information on their websites, as reproduced

(without correction) below.

https://shop.mattressonline.co.uk/Recycling

in the UK alone, an incredible 8 million mattresses are disposed of every year

work in partnership with The Furniture Recycling Group (TFRG)

TFRG separates out individual mattress components. These are then distributed to industries

that can benefit from these raw materials. Whether it's the steel used within the mattress

springs, or the comfort fillings such as wool and cotton - components are re-processed by all

sorts of different manufacturers.

by choosing to recycle, 100% of your old mattress can avoid landfill!

TFRG are able to recycle an impressive 7,000 mattresses every week - that's over 350,000

every year! In fact, over the last four years, TFRG have managed to save a volume in landfill of

4,720 double decker buses

You can recycle your old mattress when you purchase a new one - for only £24.99!

…have your old mattress ready at the time of your delivery, without any bedding. When your lovely new mattress arrives, our delivery drivers will collect your old mattress to be recycled!

https://www.dreams.co.uk/recycling-services

http://circom.co.uk/ (formerly Wastecraft)

Our recycling service lets you focus on the arrival of your new bed or mattress, without having

to worry about the time and effort of disposal. We have developed a service that’s fast,

convenient and environmentally friendly; we pick up your old bed or mattress directly from

your home when we deliver your new one, and recycle your item at our own specialised bed

and mattress recycling centre.

• 02476 100 189 / info@circom.co.uk

We're committed to the environment and make sure that no part of your old bed or mattress

reaches a landfill.

All recyclable materials are reused and all other waste is turned into green energy.

We will provide you with a green bag to seal your old mattress in prior to delivery.

We can recycle your goods Monday to Saturday from 8am - 6pm

6.2.1 Metal springs

These are melted down and processed at a metal recycling plant where they are melted down and cast back into new light iron products.

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6.2.2 Foam

Some mattresses have a layer of latex or foam for padding. The foam is either baled and sent to a waste-to-energy plant for energy from waste generation, or cleaned and used in the manufacture of industrial carpet underlay.

6.2.3 Mattress filling (wadding)

Most mattresses, unless they are memory foam, will be filled with wadding of some kind. Polyester wadding is utilised in the fibre blending industry as a replacement for virgin materials. Once reprocessed, the polyester fibres are used in various manufacturing processes including the filling of pet cushions.

6.2.4 Low-grade fabric

Mattress covers and other material including shoddy fibres are generally very difficult to recycle. This is due to the varying levels of contamination and the limited legally compliant end markets for these materials. The materials are processed into refuse-derived fuel for use in energy from waste facilities as a sustainable alternative to fossil fuels thereby creating renewable green energy and heat. Allsopp says, ‘We are constantly looking at new legally compliant recycling outlets for these materials.’

Firstly, we disassemble your mattress. All the different materials are separated and

compacted into large bales to help save space when we transport to other recycling

destinations.

We send metal springs to a metal recycling plant where they are melted down into new light

iron products. Polyester padding is used by the fibre blending industry and can be used in

various things, even the fillings in your pet’s cushions! The foam in your mattress is used in

either energy from waste generation or it can be cleaned and used to make carpet underlay.

It’s difficult to recycle mattress covers due to hygiene, so they are turned into fuel as an

alternative to fossil fuels, creating green energy and heat.

We are constantly working alongside our recycling partner to research and explore new uses

for the parts of your mattress.

To make sure we can take your mattress away as quickly as possible we ask that you seal it with tape inside the bags we supply you with for hygiene reasons. Super King (6ft) mattresses won’t entirely be covered by the bag. To wrap these, slit the side of the bag and seal it with tape on the protruding edge

Our prices for recycling vary depending on what item you'd like us to take away. Single mattresses - £23 Double mattresses - £33 King & super king mattresses - £38

http://www.matt-uk.co.uk/

Matt UK Ltd is part of HTL Recycling & Waste Management Services. We are one of London’s leading recycling and waste management specialists. We have over 30 years experience of servicing London and the South East.

Since 2008 Matt UK are the largest and longest serving Mattress Recyclers in the UK.

Matt UK Ltd, deconstruct the mattresses by hand, while this is laborious and can be time consuming task it produces a higher rate and quality of recyclable materials recovered,

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compared to alternative than shredding mattresses mechanically, or other types of un-proven machinery.

So far we have established than in some higher quality mattresses there are 17 different materials than can obtained from the recycling process, ranging from the obvious steel and cotton, which have established recycling route, through to horse and coconut hair which have no current market but can be used as a biomass application. (There are very few or/RDF Refuse derived fuels)

The Recycling Procedure

1. Mattress Arrives in various forms – (weighed on and off counted – Ticket produced)

2. Visual inspection into Good, or poor quality material – Documentation checked and confirmed

3. Mattresses will be de-constructed to retrieve valuable commodities, such as PU Foams and Polyesters

4. The components are then baled and reprocessed into the material markets,

5. <7 % will be direct into RDF due to high contamination

Matt UK Ltd was established to create a viable solution to an ever-increasing market, classed within the recycling industry as a difficult waste. We opened our first recycling centre in 2009 to create a solution for mattresses, furniture and bulky waste. Matt UK Ltd.’s main recycling centre operates out of 12-acre site in Chatham ME4 4SR.

Matt UK Ltd guarantees 100% landfill avoidance on all mattresses.

The National Bed Federation (“NBF”) estimates that approximately 2 million various sized mattresses are manufactured in the UK every year. This figure does not include the mattresses that are imported into the UK on an annual basis. The average budget double mattress weighs 35 – 50 kilos. The annual contribution of mattresses to the waste stream is estimated to rise from 160,000 ton to 245,000 ton by the year 2016.

With the lack of mattress recycling alternatives in the UK, Matt UK Ltd have established themselves as the leader in this field. Matt UK reclaims and recycles, cottons, Polyester, woven pad, metal and foam. Each material has its own varying commercial use. All recycled mattresses benefit various industries e.g. steel manufacturing, textile manufacturing and carpet manufacturing. This in turn creates gainful employment and reduces high dependency on landfill.

With the continued growth in mattress production, there is need for mattress recycling to cope with the ever demands for mattress producers.

Matt UK Ltd, where possible and agreed, donates all reusable mattresses to registered charities.

Matt UK Ltd has recently formed a partnership with Spring Forward Limited (which is part of London Community Resource Network (“LCRN”)) to divert mattresses and recyclable goods from the household and commercial waste streams and to maximise reuse and recycling opportunities.

We also aim to enhance employment and training opportunities to London residents – with a particular emphasis on the disadvantaged labour market – to contribute to the Green Jobs Agenda and Social Economy.

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Matt UK Ltd also works in conjunction with various recycling companies through out England & Wales to maximise recycling opportunities. These depots are currently based in Rugby, Birmingham, Yorkshire and Rhymney in Gwent.

http://www.aatrecycling.co.uk/

info@aatrecycling.co.uk / 0330 133 0166

We reduce the amount of mattress and sofas going into landfill and supply alternative reuse

method. Our service will provide environmental benefits and also a cost effective solution to

these bulky items

Mattress Recycling

100% RECYCLING SERVICE

Mattresses AAT Recycling

collection available

AAT Recycling will provide innovative thought and practise in the recovery of recyclable matirials, making use of all the elements that we can recover. AAT recycling identify second use markets for recovered materials from incomming waste streams, giving us a clear plan of action from the start of the process to the very end.

One Mattress takes Ten years to decompose!

AAT Recycling are committed to increasing the percentage of materials recovered reducing the amount of waste being landfilled. We also aim to raising awareness of the benefits of using matirials and fibers that have been recovered.

We can recycle one mattress minutes!

Mattress Recycling Telford

Explore AAT Recycling

Our History

From a very humble background AAT Recycling was raised from the ground based on identifying problematic areas of the recycling process. With many hours researching these issues AAT Recycling made good progress speaking to councils & contractors and many people who deal within this sector.

All of which became clear that bulky items are an issue and most if it goes to landfill.

From our findings we decided to deal with specific items Mattresses, Bed Sofas and chairs

1 Identify the items elements

We will decide if the item can ber reused , if this is not possible then we will look into other

avenues of usage.

2 Refurbish & Salvage

If the item fits our reuse programme we refurbish the items, replacing any components from

new or previously salvaged items.

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3 Recycled and Reused

A percentage of items that have gone through our reuse program are available for charity's if

we collect off your company and you support a local charity we can make arrangement's for

this to benefit them. Ask us for more information.

The Facts Mattresses in landfill

FROM ONE COUNTY ALONE.

Tonnes 350

Route Master Buses 27

Men 249917

Pigeon's 119047.61

Ford Fiesta's 200

http://www.collectyouroldbed.com/

With prices starting as little as £11.99 we are one of the lowest bed & mattress collection and disposal companies in the UK.

https://www.dreams.co.uk/recycling-services

Recycling Services

Our recycling service lets you focus on the arrival of your new bed or mattress, without having to worry about the time and effort of disposal. We have developed a service that’s fast, convenient and environmentally friendly; we pick up your old bed or mattress directly from

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your home when we deliver your new one, and recycle your item at our own specialised bed and mattress recycling centre.

OUR RECYCLING SERVICE:

ZERO TO LANDFILL: We're committed to the environment and make sure that no part of your old bed or mattress reaches a landfill.

RECYCLING: All recyclable materials are reused and all other waste is turned into green energy.

PACKAGING: We will provide you with a green bag to seal your old mattress in prior to delivery.

Reproduced from The Scotsman

“A new mattress recycling facility, the first of its kind in Scotland, has opened on the outskirts of Edinburgh. It has been designed to tackle a major problem that sees 12,000 tonnes of waste being dumped every year north of the border.

“Around 500,000 mattresses go to landfill annually in Scotland, part of around 7.5 million across the UK. Until now the bulky items have been disposed of in this way, taking up a lot of space and presenting an environmental hazard. Ken Chrystal, site manager at Hamilton Waste & Recycling, designed the new system. He hopes to process 100,000 mattresses this year – around a fifth of Scotland’s total mattress waste – and more in future.

“The firm has already signed deals with three local authorities in Scotland, and has received interest from England and Wales. Talks are also under way with some of the country’s leading bed retailers, which offer customers an uplift service for used mattresses.

“Five full-time workers are now employed at the specialist plant, located at Carberry in East Lothian. “Mattresses going to landfill is a huge problem nationally,” said Chrystal, “partly because of the enormous volumes of space they take up, but also because of their nature – they create voids which fill with poisonous methane and can explode. “Landfill sites hate them because they cannot be compacted, plus they’re potentially hazardous and harmful to the environment.”

“The average mattress weighs around 28kg. Although they are labour-intensive to deconstruct, there is up to 10kg of valuable scrap steel in the springs in each one, and around 20kg of various grades of textiles.

“We recover the steel, as well as cotton, shoddy fibres, polyester, ticking, coconut hair – some materials have value, others have none,” said Chrystal. “Recovered fabrics such as polyester are collected and go back into manufacturing, possibly to make new mattresses, while waste latex and foam can be chopped up and reused to make things such as carpet underlay. There is usually a part of the outer fabric that is too wet or heavily soiled to be reused, so this is used locally as fuel to produce green energy. With this new plant we can guarantee 100 per cent landfill avoidance.”

“Hamilton Waste and Recycling recently became the first Scottish company to be awarded the Green Compass PAS 402 accreditation for recycling excellence. The firm, which employs around 100 workers, also has specialist facilities for recycling plastics and building waste such as

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plasterboard and wood. It was awarded £117,678 from the Circular Economy Investment Fund to drive the new project forward.

“The £18 million fund offers investment and supports work that will deliver circular economy growth. It is administered by Zero Waste Scotland and backed by the Scottish Government and the European Regional Development Fund.

“Iain Gulland, chief executive of Zero Waste Scotland, said: “Mattress recovery is a circular economy opportunity for Scotland that we have been pursuing for a number of years, and to see mattress reprocessing becoming possible on Scotland’s shores is a fantastic achievement – not just for the environment but for the Scottish economy. The Circular Economy Investment Fund offers businesses financial support to make transformative projects happen.”

“Hamilton Waste and Recycling is aiming to process 2,000 mattresses a week, but Chrystal says

there is potential to massively increase that number. “We’re not at full capacity yet, but the site is fully operational and we will continue to expand and adapt,” he said. “I’m hopeful this will become the norm, once people see the environmental benefits.”

By Ilona Amos, 27 January 2018

https://www.scotsman.com/news/environment/mattress-recycler-bids-good-night-to-scottish-waste-nightmare-1-4674516

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Annex C : Shortlist of recyclers contacted

AAT Mattress Recycling

Amgen (Bryn Pica)

CAD Recycling (including Collect Your Old Bed)

Circom

Eco Mattress Recycling

EOL Recycling

Matt UK (Part of HTL Recycling & Waste Management Services)

The Furniture Recycling Group

Ulster Social Employment Ltd

Following the company’s exposure in the Scotsman, we also contacted Hamilton Waste & Recycling. Because the site manager kindly spent a great deal of time informing us of his processes and outputs, we did not then also send a questionnaire.

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Annex D : Questionnaire

Question – for quantified response Reason/expected output

How many mattresses do you receive and

what are your main sources of mattresses (e.g. retailer or manufacturer take-back schemes; contract e.g. hotels, prisons, hospitals; local authorities, etc.)?

An attempt to reconcile data from earlier studies on whole mattresses and to confirm that the majority of the UK mattress recycling sector has been covered.

How many mattresses do you dispose of whole, i.e. without deconstructing?

To assess rate of disposal by means other than recycling, again, to ensure that we have a reasonably captured the majority the net quantities sent for recycling.

What are the approximate mixes of types and sizes of mattresses received?

An attempt to reconcile data from earlier studies on whole mattresses

What are the quantities or weights of the components retrieved from deconstruction and what were their end fates (e.g. reuse, recycling, incineration, landfill, or export – where the end fate is unknown)?

The main reason for the survey – to establish a component recycling rate by component type. The data would also provide an up to date analysis of the mix of components in a ‘average’ mattress.

Question – for qualified response Reason/expected output

Which components are the most difficult to find outlets for, and why?

Information to confirm the barriers and opportunities in the sector and to inform possible intervention policy

What are the trends that you see in the number and types/sizes of mattress received and in the markets and prices for the components?

What new technologies are there in the industry that affect your operations?

Other – any additional comments

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Annex E : Comments from recyclers taken from survey returns

“In the past year we have deconstructed approximately 30,000 mattresses (c.720 tonnes). All metal components go through [a local company] for further recycling and are then exported for reuse. We send a truckload of bed springs to [recycler] about 5 to 6 times a week. Each truckload has an average of 100 spring frames and each load weighs an average 1 tonne. Approximately 45% of other materials (shoddy felt, polyester etc) are exported to [area] for further recycling or reuse. Approximately 55% of other materials go to local companies for further recycling and end up as solid derived fuel, used to fire the kilns in the cement industry.”

“All the materials (metals, polyester, shoddy felt etc) derived through our mattress deconstruction processes are separated and sent for further recycling or reuse are weighed at their final destination and we receive that information back, usually in the form of a weighbridge docket. We then accumulate all the figures from our outgate and that's how we arrive at the average of 25 kg per mattresses received into our facility. The mattresses we process, depending on size and quality, can weigh from 10 to 70 kg but the approximate average weight of the mattresses we receive per annum is 25 kg.”

“The main issue is the availability and sustainability of end markets for the majority of textile, fabric and foam elements, although we are beginning to see some interest. The markets for components has been poor, but there is now some interest generating in textiles/fabrics. It’s most difficult to find outlets for shoddy, ticking, foams… all fabrics except polyester. We’re seeing an increasing number of mattresses. The market for steel has been static.”

“All components are challenging. There aren’t many components that have multiple outlets. Foam is challenging due to the BS standards for reuse being very tight for foam manufacturers. There are limited outlets for polyester; pocket springs have limited outlets and no rebate due to the fabric.”

“Shoddy fibre and mattress covers have no fully compliant outlets in the UK. Textile recycling in the UK for this material is non-compliant on a number of fronts, so low grade fibres like this need to go to energy from waste. The high calorific value makes it awkward for refuse derived fuel, so it has to be blended with other waste types.”

“I think the NBF could be valuable to recyclers by putting pressure on the Environment Agency to lobby for retailer EPR on mattress, or a ban on Mattresses to landfill. At present where landfill operators take mattresses, then local councils have little interest. Focus needs to be on the local authority.”

“Retailer recycling is highly competitive to the level it is almost unsustainable. At present there is no support for mattress recyclers. Hence why there are now less than 6 reliable recyclers in the UK that are fully compliant. Some of which cannot make this commercially viable unless it is supported by other waste streams.”

“Trends:

– Mote retail volume after new year’s sales and Easter sales etc.

– Mainly double and king size from retail, all sizes from local authority

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– No one want to pay anything for [components] naturally. So finding outlets is a constant challenge.”

“Steel prices are fine: that’s not a problem. The problem is not prices but markets. Cannot find market for coconut, coir and cotton. There is no outlet for hard point shoddy. Can only get rid of exactly the same stuff that was getting rid of at the last survey, namely: foam, springs, and poly. All non-recyclable textiles are baled and sent via a broker to energy from waste.”

“There are many unproven machines [available in the industry].”

“The numbers [of mattresses received] are very seasonal.”

“UK markets [for components] are very poor due to lack of manufacturing.”

“Value [of prices for components] depends on quantity and quality.”

Value-driven consulting

Science-led research

Oakdene Hollins Ltd Ardenham Court Oxford Road Aylesbury Buckinghamshire HP19 8HT +44(0)1296 423915 admin@oakdenehollins.com www.oakdenehollins.com www.remanufacturing.org.uk www.uniformreuse.co.uk www.remancouncil.eu www.eu-ecolabel.uk Registered in England&Wales no: 2937129

About the authors

Stephen Slater MA, Principal Consultant

Much of Steve’s consultancy experience has involved leading research and analysis projects for key public and private sector organisations in the field of waste management, resource efficiency and sustainable technologies. He has advised a major national retailer in its commitment to eliminate landfilling of operational waste and has been directly involved with the client in implementing its plans.

Katie Baker MA (Oxon)

Katie’s role as Projects Administrator means that she can get involved at early stages of our projects – as in this case to assist in data gathering – as well as taking responsibility for final production of reports.

From its offices in Aylesbury and Brussels, Oakdene Hollins provides research and consulting services to clients under three main themes:

• Circular Economy • Sustainable Products • Innovative Technologies & Materials For more information visit oakdenehollins.com