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The complete solution

for polyurethane
foam recycling

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intelligent

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USE OF RESOURCES

is a business necessity

In todays business environment, intelligent use of

resources is a necessity. Regulations require it, and

the competitive environment demands it. The winners in todays competitive

marketplace will be those who creatively use their resources to full potential.
Mobius Technologies was formed to help the polyurethane industry realize this
potentialthrough a recycling technology that reintroduces scrap polyurethane
into the new-foam manufacturing process.

The Mobius Advantage

Mobius means recycling. Staffed by a
group of experienced engineers and scientists from the polyurethane and plastics
industries, Mobius has focused its efforts
on the commercialization of polyurethane
recycling systems. With expertise in
chemical and mechanical engineering,

process design, chemistry, and

process control, Mobius has developed
a profitable, reliable method for recycling
polyurethane. Our efforts have produced a
system that achieves dramatic manufacturing cost savings for polyurethane
foam manufacturers.

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The Mobius Recycling System

manufacturing

The Mobius system is a complete solution

for processing scrap foam and reintroducing it into the new-foam manufacturing
process. Mobius provides the equipment
and the necessary process development
to provide the foam manufacturer a
turnkey system for recycling scrap foam
on site. Each Mobius system is custom
engineered to meet specific process and
formulation requirements. Scrap foam
content of 20 pphp (parts per hundred
polyol) is being achieved commercially.

COST SAVINGS
for polyurethane foam manufacturers

FOAM

SCRAP FOAM

PROCESS
FLOW

GRINDING

MIXING

GRINDING

MILL REDUCING

SCRAP FOAM TO POWDER.

STORAGE

SCREENING
RECYCLED
POWDER

Grinding and Screening

The Mobius system grinds scrap foam
into powder and reintroduces this material
to the new-foam manufacturing process.
The scrap foam comes from the manufacturing process or from post-consumer
recycling. The foam pieces are first
ground to a size of about 10 millimeters
(1/2 inch), then fed to a grinding plant
that reduces the foam to an average size
of 50 microns.
Numerous plant functions are monitored
by computer, allowing the plant to be
operated safely and reliably with a minimum number of operators. Plants capable
of continuous outputs of 100 kg/h
(220 lb/h) to1000 kg/h
(2200 lb/h) are available.

Mixing and Pouring

Reintroduction of the polyurethane
powder is accomplished by blending the
powder with the polyol component. The
system blends and meters the powder/
polyol mixture, producing foam with powder content up to 20 pphp, depending on
the foam formulation and process design.
Mobius is staffed with scientists and engineers from the polyurethane industry and
can assist in the development of formulation and process changes.
Recycled Powder Compatibility
Unlike mineral fillers, the recycled
polyurethane powder has the same density
as the new polyurethane that makes up
the foam structure. The powder is also
very similar chemically to the new
polyurethane. Because of this similarity,
the powder is very compatible with the
rest of the foam, so an essentially homo-

1.0 mm
FOAM

WITH

10%

RECYCLE CONTENT.

geneous structure is formed. During the

foaming reaction, crosslinking between the
powder and the isocyanate can occur,
further integrating the powder into the
foam structure. With minor formulation
changes, foam can be made while maintaining all foam properties, including
density, compression set, resilience, tensile strength, tear strength, and elongation.

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Benefits of the recycling

process

Proven technology that works

in the real world

Present recycling opportunities for foam

manufacturers are typically limited to
rebonding of scrap foam. Because of a
large supply and relatively low demand,
scrap foam prices are much lower than
the foams original manufacturing cost.
Therefore, a process that can reintroduce
this low-value scrap as an additive to
virgin foam can offer tremendous
cost savings.

Mobius designs systems that work in the

plant environment. We have a solid manufacturing background, and it shows in the
equipment and systems we build. We
design our plants to be reliable, and simple to operate and maintain. We design
the system with the operators in mind
local analog instrumentation indicates the
current status of important plant functions. These local instruments are backed
up by a computer monitoring system that
continuously monitors and reports all
plant parameters.

Additional benefits
You can also:
Improve your competitive position by
lowering your manufacturing cost.
Turn costly waste into a valuable asset.
Take scrap back from customers
providing them with a valuable service.
Help the environment by reducing the
amount of scrap waste and by reducing
the use of volatile organic chemicals.
Utilize the process as a public relations
tool, promoting green manufacturing.

The computer system, using a programmable logic controller, logs all data,
maintains historical records, and
provides trend analysis for preventive
maintenance. The system also allows
Mobius to monitor and troubleshoot
the plant remotely via the Internet.

THE

COMPUTER SYSTEM CONTINUOUSLY MONITORS

ALL PLANT FUNCTIONS.

SETTINGS

CAN BE EASILY

VIEWED AND CHANGED ON THE COMPUTER TOUCH

SCREEN WITH A FINGER TOUCH.

POWDER

IS LOADED INTO

STORAGE BAGS.

GROUND

FOAM IS

BEING LOADED ONTO

A CONVEYOR BELT.

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Improving your bottom line

The Mobius recycling system proves itself
where it really counts, on the bottom line.
The graph on the right shows the results
that can be expected. With typical processing cost of less than $0.30 per kilogram ($0.15 per pound), manufacturing
cost savings are substantial. Customers
have experienced foam-manufacturing
cost reductions of as much as 5 percent,
even accounting for a scrap value of
$0.55 per kilogram ($0.25 per pound).
These savings provide a significant profit
contribution. A plant that pours 5 million
kilograms (11 million pounds) per year
can achieve gross margin improvements
of more than $500,000. Contact Mobius
for an in-depth analysis of how much
profit a recycling system can add to your
bottom linewe know youll be
impressed.

7.5

5.0
MANUFACTURING
COST SAVINGS (%)

2.5

0
0

10

15

20

25

POWDER CONTENT (PPHP)

DRAMATIC

COST SAVINGS CAN BE

ACHIEVED USING THE

MOBIUS

RECYCLING SYSTEM.

PNEUMATIC

CONVEYING SYSTEM

DUST COLLECTOR.

Mobius can

QUICKLY MOVE

from concept to implemented solution

Evaluating your returns

Laboratory Services Program

Mobius can help you determine the economic benefits of a Mobius recycling system. Our Recycle Economic Analysis
Program evaluates installed costs, operating costs, and investment economics. The
program shows the returns you can expect
to achieve from a Mobius recycling plant.

From pilot plant trials through formulation

changes, Mobius provides the assistance
you need to optimize the recycling process
for your production environment. Our inhouse pilot plant and laboratory can be
used for pilot trials, scale-up, and process
development. Contact us for details.

Getting started

Training and technical service

Mobius is ready to start helping you

achieve results today. With a dedicated
staff of engineers and scientists and complete laboratory and pilot plant facilities,
Mobius can quickly move from concept to
implemented solution.

From initial operator training to on-site

troubleshooting, Mobius is committed to
exceeding your needs. Our staff of experienced scientists, engineers, and technicians is ready to help you, with immediate
support via phone and computer, and onsite technical service. Our rapid response
commitment means we do whatever it
takes to keep your plant running reliably,
efficiently, and profitably.

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Recycling background
information
Following are three articles on the
polyurethane recycling process that are
available from Mobius:
H. Stone, S. Lichvar, and F. Sweet,
Commercial Potential for Recycling
of Finely Ground Foam in Flexible
Polyurethane Foam, J. Cellular
Plastic, 33, 330-371 (1997).
J. Jensen, Real-World Economics of
Polyurethane Foam Recycling,
Proceedings of the May 2000
Polyurethane Foam Association
Conference.
B. Villwock, et al,Recent Technical
Advances in Recycling of Scrap
Polyurethane Foam as Finely Ground
Powder in Flexible Foam,
Proceedings of API Polyurethane
2000.

Mobius Technologies, Inc.

900-A Golden Gate Terrace
Grass Valley, California
95945
Telephone 530-477-1689
Fax 530-477-1696
info@mobiustechnologies.com

www.mobiustechnologies.com

2000 Mobius Technologies, Inc. Br 0004

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