Mattresses are one of the main contributors to global landfill waste due to the complex combination of materials glued together. An estimated 1.5 million mattresses are disposed of every year in the Netherlands alone, 35 million in Europe and 20 million in the US. An increased focus on recycling by mattress manufacturers has grown the demand for reduced materials complexity and new ways to connect layers in a reversible manner.
Now, Royal Auping and DSM-Niaga have redesigned the mattress to make it fully recyclable. Every component of the new modular design can be separated easily and can be reused in a new mattress.
“Conscious of the fact that most mattresses end up in landfill or incinerated, we used all of DSM-Niaga’s materials science to meet Auping’s demands for quality and comfort, by using only materials that are known for no negative impact on our health, fully recyclable into new mattress components, and connected in a reversible way,” says Kelly Hall, managing director, DSM-Niaga.
“We have been impressed by the dedication of the Auping team to find new ways of manufacturing, and we are truly impressed by Auping’s knowhow of the nightly hours we use to recharge.”
Royal Auping and DSM-Niaga have developed an alternative for mattress manufacturing, including local recycling, that also enables frequent maintenance for quality and hygiene purposes. The first mattresses will be placed in Landal GreenParks resorts (a European network of holiday villages) before the end of the year.
The mattress has good airflow and has a modular design that consists of six components – the ticking, comfort layer, pocket spring, felt floor, zippers and tape rush, that are brought together by yarn and a reversible adhesive.
All components can be easily replaced when comfort or hygiene demands, securing a good night’s sleep, according to the company. The collaboration of local production and partners, all within 60 miles of the Auping factory, facilitates local recycling without compromising on quality.
In the collaboration with DSM-Niaga, Royal Auping used its experience in manufacturing high quality mattresses and has now added circularity as a leading factor.
“Comfort and body support have been crucial for as long as Auping has existed. Over the years our focus shifted from the product to the actual service we provide to people every day – a good night’s sleep,” says Jan-Joost Bosman, CEO of Royal Auping.
“This new focus introduced new design challenges as airflow through the mattress, replacement of end-of-life parts, and the impact of all elements on our sleep and long-term health.”
