Recover, reuse, and recycle: Paving the way for sustainable polyurethane
Trelleborg Applied Technologies
The challenge
Trelleborg Applied Technologies specialises in advanced material solutions, including polyurethane, glass microspheres, epoxy tooling, and engineered rubber products. The company delivers high-performance, quality-assured materials for demanding environments – from deep-sea to aerospace applications.
As an industry leader in sustainability and in support of the United Nations (UN) Sustainable Development Goals, the Retford-based firm identified a clear need for a more sustainable approach to polyurethane (PU) manufacturing – one that enables the recovery, reuse, and recycling of materials without compromising performance or quality.
To accelerate innovation in sustainable materials, Trelleborg has launched Polymers for Tomorrow – a dedicated task force focused on forging partnerships in three key areas: bio-based materials, regenerated and recycled materials, and new polymer formulations. By collaborating with academic researchers, start-ups and suppliers, Trelleborg aims to enhance circularity and drive the sustainable production and use of advanced materials.
Trelleborg Applied Technologies’ Innovation Director, Adam Nevin, is no stranger to the KTP process – having originally joined the company in 2018 as a KTP Associate before progressing to lead the Innovation Team.
“The KTP has strengthened our focus on sustainability, driving the internal recycling of polyurethane offcuts and reinforcing Trelleborg’s Sustainability Development Goals. We’re now on track to become a leader in recycled materials within the Group.
Becky has been essential in training new R&D team members. The knowledge from this project has been compiled into training documents and a comprehensive manual, along with work instructions for specialist equipment.
As a KTP alumnus myself, I’ve now seen both sides of the KTP and have found the experience enriching each time. As an Associate, I found the personal development exceptional, while as an Industry Supervisor, I found the support and dedication of all parties to the task at hand to be phenomenal. I can’t recommend them highly enough!”
What we did
Knowledge Transfer Partnerships (KTPs) are a three-way collaboration between a UK-based business or charity, a research organisation, and a qualified graduate known as a KTP Associate, who has the capability to lead a strategic business project.
Over a 19-month period, the KTP saw Trelleborg Applied Technologies partnered with chemical engineer and project manager Rebecca Randle, under the supervision of Professor Peter Licence – Head of the School of Chemistry and Director of the GlaxoSmithKline (GSK) Carbon Neutral Laboratory and Professor Simon Woodward – Co-Director, EPSRC Centre for Doctoral Training in Resilient Chemistry, both at the University of Nottingham.
The project focused on life cycle assessment (LCA) modelling of Trelleborg Applied Technologies’ internal products to evaluate the carbon footprint of existing materials and processes. These were then benchmarked against more sustainable alternatives, including carbon-negative raw materials, recycled content, and cold-cure versus oven-cure techniques, as part of a broader initiative to embed sustainable thinking across the business.
The LCA also revealed that a significant portion of Trelleborg Applied Technologies’ PU waste could, in fact, be reprocessed into a usable thermoplastic. For the remaining non-recyclable materials, viable cross-linkers were identified to enhance material recovery potential.
Speaking about the project Professor Licence shared:
“This KTP has delivered real, measurable impact – not only advancing sustainable practices at Trelleborg, but also enriching our teaching and research. It aligns strongly with the University of Nottingham’s commitment to the UN Sustainable Development Goals and demonstrates how academic collaboration can drive meaningful industrial innovation.”
The impact
The collaboration has delivered significant, measurable benefits to Trelleborg Applied Technologies. Most notably, the project uncovered that a substantial proportion of the company’s processed PU waste can be reprocessed into usable thermoplastic materials, presenting a clear opportunity to reduce production waste by up to 25% and support sustainability and cost-efficiency goals.
The introduction of LCA modelling has transformed decision-making processes. By enabling data-driven comparisons of materials and procedures, LCA has allowed the company to justify resource-efficient and environmentally responsible strategies. This shift toward evidence-based sustainability is expected to enhance operational efficiency and contribute to long-term profitability.
Becky remains at Trelleborg Applied Technologies on a permanent contract as a Project Manager, transitioning early from her role as KTP Associate to deliver a substantial R&D project for the company. Speaking about the experience, Becky explained:
“I found the KTP to be the perfect crossover from academia to industry. Seeing all the different elements of working in both allowed me to grow my skillset and find whole new development areas. The personal development fund and residential training were invaluable and really allowed me to seek out specific training and personalise my development plan.”
The KTP was successfully completed by KTP Associate and postdoctoral green chemistry graduate, Jessica Streets, who joined Trelleborg for the remainder of the project. The overall experience has led Trelleborg Applied Technologies to continue this work, further enriching its Sustainable Development Goals.
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