Product Opportunity Summary: Mattresses

Transcription

1 April 2013 Product Opportunity Summary: Mattresses Priority action areas for mattress retailers and manufacturers to reduce the carbon, energy, material and waste of their products. Setting priorities and identifying opportunities Significant developments in the range of used within mattresses on the UK market in recent years has seen the more widespread use of latex, memory foam, wool, bamboo and coir. However, few studies have examined the overall impact of different mattress types or their carbon footprints. So, where should the mattress sector go from here? What are the main? New WRAP-funded research, Opportunities for reducing the of home products, provides an overview of the carbon, energy, material and waste of the UK mattress sector, using available data. What should we do about it? The research then quantifies the most significant opportunities to reduce these, based on current or potential examples. Showing which actions are likely to be most effective will help producers and retailers to prioritise areas for further investigation. How can we find out more? This document summarises those main opportunities, illustrated using real-life examples. Links to the full report and other product opportunity summaries are outlined in the Further information section. page 1 forward

2 What are the main? New WRAP-funded research uses extensive data analysis to calculate the level of impact (in terms of carbon, energy, material use and waste) resulting from mattresses for the whole UK market. Life cycle assessments (LCAs) for mattresses are quite limited in number. None provide a ranking of different mattress types in terms of. However, all available studies show that: the impact of mattresses is dominated by the generation and processing of the such as steel, foams and fillers; and Due to hygiene issues re-use is a less viable option for used mattresses making disposal the second highest impact area. The typical mattress used in UK households is a sprung mattress comprised of steel springs with various fillers. Using this as the most representative product, and scaling it up to UK level, indicates that the design and manufacture of mattresses sold on the UK market on an annual basis: generates 440,000 tco2e in greenhouse gas emissions; uses 60,000 MWh energy and 170,000 tonnes of material. These cover raw material extraction and production as well as the mattress manufacturing stage. Scaled based on an estimated UK annual sales volume of 169,000 tonnes (source PRODCOM/WRAP). Source: Opportunities for reducing the impact of home products page 2

3 Choice of is a key element in the design and marketing of mattresses. The bulk, softness and resilience of fillers, or the thermo-regulation properties of ticking, are the subject of in-depth research and development. Materials are also the dominant factor within a mattress s overall footprint. Any mattress producer or retailer wishing to address sustainability issues needs to look carefully at material choice and as the top opportunity for achieving reductions. The growth in the market for high-end organic mattresses, consumer concern over in-use emissions and expectations of responsible brand behaviour indicate that there may be business benefits too. Due to lack of data availability, the WRAP-funded research was unable to quantify the relative of mattresses based on material composition. To date, no LCAs have ranked different mattress types. Are natural such as wool, bamboo, coir and natural latex always the best option? Are there trade-offs? Do some have a low carbon footprint but a high level of hazardous chemicals used in processing? Where should you start? Investigate the of the you currently use. Consider if there are alternative with the same performance but lower impact talk to your suppliers. Unfortunately there is no handy summary of the key per filler material and their relative performance. However, the research undertaken to inform the recent revision of the EU Eco-label for mattresses provides detailed information and suggests criteria for key such as polyurethane foam and latex. See: Other sources of performance criteria* for mattress include: Case Study Advansa produces fillers and ticking fabrics used in the mattress industry. Carbon footprint information is available for several of its products such as Thermo Cool Eco products. According to Advansa, the production of the polymer used for these products reduces CO 2 emissions by up to 63% and requires up to 30% less energy, compared with the production of an equal amount of Nylon 6. Oeko-Tex 100 CertiPUR No time for an in-depth assessment? Examine recycled options as outlined on the next slide. EuroLATEX Eco-Standard * For information purposes only, WRAP do not endorse these schemes. page 3

4 (part 2) Environmental benefits of recycled : The recycled content of raw used has a significant influence on GHG emissions, energy, resource use and waste. If 50% of used in mattresses and their packaging were composed of recycled content, the WRAP-funded research suggests that annually, on a UK-wide level, compared to a no recycled content scenario this would save approximately: 150,000 tco 2 e ~ this is a 34% reduction in the current carbon impact of mattresses; and 85,000 tonnes in saved virgin. Polyurethane (PUR): It is possible to produce PUR with recycled content using a process called glycolysis. This process can combine industrial and postconsumer polyurethanes to create new polyols, a raw material used to make polyurethanes. Alternatively, according to the Polyurethane Foam Association, foams which incorporate material derived from plants such as soy and castor beans can offer promising property improvements, including better resistance to yellowing and slightly better mechanical properties, such as support factor and dynamic flex fatigue. Steel: Using recycled steel is a double win-win - it is often significantly cheaper (-40%) and brings savings. Every tonne of recycled steel saves 40% of the water required for virgin steel and uses only a quarter of the energy. Note that recycled stainless steel does not have such strong benefits. Sealy, a leading mattress manufacturer, states that 100% of the steel products in Sealy sleep sets (e.g. innersprings) come from recycled steel. Hoteliers such as the Radisson Blu Edwardian need high performing, durable mattresses and their mattress provider, Perpetua, has demonstrated that this can be combined with lower impact at the desired price point. The tailored version of their Vertue mattress for the Radisson Blu Edwardian comprised: springs made from 90% recycled steel; and 100% natural wool and silk quilt The mattress exceeded the specification and comfort levels required and was supplied at 25% less cost than leading competitors. Following an intensive 3-month trial, the hotel guests reactions were highly positive and the mattresses were chosen to be installed in all the group s hotels around the UK. page 4

5 Low quality mattresses will tend to have a similarly low lifespan, ultimately proving expensive both in terms of impact and cost of ownership, due to the need for early replacement. Whilst the Sleep Council recommends giving your mattress an MOT once it reaches the seven year point, it also highlights that the useful lifespan of a mattress will vary depending on quality and use factors (e.g. amount of use, weight of user). Why do mattresses need replacing? Loss of bounce and support Hygiene Allergy reasons (e.g. bed bugs) Change in user requirements The typical lifespan of a domestic mattress is broadly 810 years. In the UK, the Sleep Council advises householders to check their mattresses at the 7 year point to ensure they are still fit for purpose. No-one is suggesting that mattress life should be extended at the cost of hygiene or user comfort, but what if these issues could be addressed via design modifications which reduce the need to replace the whole mattress? This could bring a triple benefit of reduced impact, cost savings for the consumer and on-going sales relationships for manufacturers and retailers. New mattress delivery and returns Consumers return new mattresses for a variety of reasons, such as the mattress not being the correct firmness or having minor faults. These mattresses are often damaged during the delivery or return trips resulting in the mattress having to be disposed of. Providing information to consumers to leave packaging on unless satisfied with the product and providing delivery teams with adequate packaging to avoid damage in the delivery and returns journeys would enable more mattresses to be resold. Modular mattress design For a sprung mattress, the springs often have a far greater durability than the fillers and fabric used in the comfort layer. Modular mattresses and sleep systems enable the top layers to be changed as required, for example because compression has occurred causing loss of comfort and support, for hygiene reasons, updated fire regulations or changed user requirements. It is estimated that mattresses with replaceable mattress tops or other components can extend mattress life significantly, by as much as five to 10 years. This type of design has the added benefit of facilitating mattress disassembly and at end of life. From a commercial viewpoint, although it may delay the purchase of complete mattresses, an on-going sales relationship can be built up with the customer. In a challenging economic climate, the ability to purchase replacement layers may provide a solution for customers delaying new mattress purchases. A self-cleaning mattress? Nanotechnology can be used to provide a self-cleaning effect when applied to mattress coverings by preventing dirt and liquids from sticking to the mattress surface. This can avoid the need for early replacement due to hygiene reasons and also minimise the need to wash mattress covers. page 5

6 Mattress disposal poses a large problem. An average mattress takes up 650 litres of landfill space as compression is difficult. In addition, mattresses can create voids, potentially causing accidents for both personnel and vehicles. Removing mattresses that have been fly-tipped is also costly. Yet the majority of reclaimed from mattresses can be recycled, such as steel, textiles and some types of foam. Although economically challenging, successful mattress schemes are being operated in the UK by retailers and local authorities in conjunction with mattress recyclers. Nearly 80,000 tonnes of mattresses are estimated to arise at Household Waste Recycling Centres per annum in the UK, with an additional 87,000 from bulky waste collections making a total of 167,000 tonnes a year. WRAP Composition and re-use potential of household bulky textiles in the UK, 2012 Recycling Mattress may take the form of shredding or manual dismantling. Although labour intensive, manual disassembly usually leads to higher levels of material and can be combined with social enterprise solutions. All main components in mattresses have potential end uses but also pose some challenges as a report for ZeroWasteScotland* highlights: Steel springs can be separated and recycled though the process is more challenging for pocket sprung mattresses. Sprung steel is not as valuable as mild steel and springs can be costly to transport if not compacted. Polyurethane foam can be chemically recycled (see previously) or shredded, rebonded and used for carpet underlay and sports surfaces. Latex foam can be used in small amounts when combined with other for carpet underlay. Textile components are often shredded for end uses such as automotive felts, but end markets can be restricted by negative perceptions of material sourced from mattresses. Pure polyester layers have high value and high recyclability. There are opportunities for many organisations such as retailers, councils, hotels and companies to work together and start take back and schemes. Current examples in the UK include Rhondda Cynon Taff council working with Amgen Cymru; Matt UK with Lewisham Council; and Airsprung with JBS fibre. * A Business Case for Mattress Recycling in Scotland, ZeroWasteScotland page 6

7 How can WRAP help you? If you wish to find out the detailed methodology, assumptions and results behind the data presented here, the full report Opportunities for reducing the impact of home products can be accessed at: Product Opportunity Summaries for other key home products including mattresses, paints and varnishes, furniture and kitchens can be viewed: WRAP has an extensive research base which provides valuable information on and reduction opportunities for a number of products including electrical and electronic goods, textiles and home products. For more information visit: How can you help WRAP? The results from the report, Opportunities for reducing the impact of home products, are indicative in many cases as the analysis used assumptions and extrapolations to overcome data gaps on a specific product s impact or actual quantified examples of reduction actions. The analysis would benefit from manufacturers and retailers using their expertise and internal data to refine the assumptions made to generate more accurate outputs. It is hoped that over time more data and insights will become available to update the data, assumptions and analysis undertaken in the report. The Product Sustainability Forum (PSF) is comprised of leading retailers, suppliers and related stakeholders seeking to take an integrated approach to reducing product. For more information see: While we have tried to make sure this case study is accurate, we cannot accept responsibility or be held legally responsible for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. This material is copyrighted. You can copy it free of charge as long as the material is accurate and not used in a misleading context. You must identify the source of the material and acknowledge our copyright. You must not use material to endorse or suggest we have endorsed a commercial product or service. For more details please see our terms and conditions on our website at back : home Waste & Resources Action Programme The Old Academy 21 Horse Fair Banbury, Oxon OX16 OAH Tel: Fax: info@wrap.org.uk Helpline freephone