At a time when thermoset waste remains one of the composite industry's most stubborn blind spots, Cannon Group has moved the conversation from theory to execution. Through its POSSIBLE (PrOduce SuStainabLE Industrial Bodies) project, the company has demonstrated viable mechanical recycling pathways for rigid polyurethane (PU) and glass-fiber reinforced polyurethane (GFRP) composites — materials traditionally viewed as end-of-life liabilities.
At JEC World 2026 (Paris Nord Villepinte, March 10 to 12), CANNON presented its revolutionary approach recycling polyurethane (PU) and PU-glass fiber composites (GFRPs).
The process has been developed in close cooperation with PU processor MAP S.p.A. and the University of Bergamo, with co-funding from the Italian strategic plan for the EU recovery fund NextGenerationEU. The project has laid the groundwork for PU and GFRPs end-of-life recycling and reuse, successfully demonstrating that ground foam and granulated parts can be used as secondary reinforcement materials in new composite formulations.
Thermosets account for about 12% of global plastic production, with over 40 million tons per year. Of these, polyurethane foams alone account for about 17 million tons, over 42%. While valued for their mechanical and thermal resistance, stability, and the possibility of incorporating reinforcing fibers, the combination of chemical cross-linking in the material and fibers makes traditional recycling almost impossible.
"In the plastics industry, sustainability and end-of-life discussions have taken center-stage, especially when it comes to reinforced thermosets," said Maurizio Corti, Corporate R&D Director at CANNON. "However, rigid polyurethane foams and glass fiber reinforced polyurethane (GFRP) composites are indispensable materials for the energy efficiency goals of automobiles, buildings, or technical equipment, even though they remain among the most difficult to recycle."
During the POSSIBLE project, two complementary approaches were explored. The first involved transforming rigid foam waste into micrometric powders, which were then dispersed into the polyol to form a slurry and dosed as a liquid component using a mixing head. The second involved using rigid PU granulate and polyurethane-glass fiber composite, introduced as a solid filler into the mixture using dedicated dosing systems combined with the FPL 36 IW mixing head for Interwet-LFI (Long Fiber Injection) technology patented by CANNON.
With the powder approach, panels showed homogeneous distribution and thermal conductivity increased by only about 4% compared to the reference, maintaining valid insulating performance with 3% recycled content. With the granulate approach, panels containing up to 40% recycled granules by weight were produced, with uniform distribution throughout the thickness.
Based on research conducted during POSSIBLE, CANNON is now working on commercially viable solutions for recycling PU and GFRPs that will enter the market in the near future.
Source: CANNON
