RetourMatras (the Netherlands)

RetourMatras is a Dutch company that has built a fully automated mattress treatment plant in Lelystad, in the province of Flevoland. This fully automated processing line has been designed and built internally by RetourMatras in partnership with specialised suppliers (RetourMatras, 2016, Zero Waste Scotland, 2013).

All mattresses collected from mattress containers are deposited directly in the storage hall, ensuring that they stay dry at all times. An electric crane is used to move the individual mattresses from the deposit point onto a moving conveyor, after which they are cut open. The predominantly cotton cover is removed using a specially developed ‘peeling roll’ and is stored separately, to be given a new life as a duster or used in new textile products.

The mattresses are then sorted by passing through a metal detector; 100 % foam mattresses go to one side of the line and mattresses with steel springs are sent to the magnet. The magnet removes the steel springs, which are melted and used again as secondary material. What remains is the foam part of the mattress. This is reduced in size and pressed into bales. The foam, polyurethane foam and latex are used in carpet underlay, judo mats, filling in the car industry, etc. RetourMatras does not make new products, but ensures that the materials obtained from the old mattresses are sent to specialised recyclers.

The plant has the capacity to process 190 000 mattresses per year (about 4 750 t/year), with a productivity of about 30 000 mattresses per worker per year. Only four members of staff are required per shift.

Retourmatras

RetourMatras produced a video to present their technology. It is available at: https://www.youtube.com/watch?v=epxWhT7e4kg