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Attempts to include ground foam by cryogenic grinding of scrap foams in the production of new flexible polyurethane foams started more than ten years ago. Current work, sponsored by PURRC (Polyurethane Recycle and Recovery Council-SPI), reports on pilot plant and full scale demonstration of the use of foams from a variety of sources, including plant fall off and post consumer foams. Ground foams were produced by cryogenic and mechanical grinding. New foams were produced at two densities and different loading levels while maintaining equal density and IFD to unfilled control foams. The study includes data on dispersion properties of the powders, foam performance and estimated economics.

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