Aug 18 2007
Most conventional mattresses contain large amounts of foam, polyester and other oil-based synthetic materials, all of which have a negative impact on the environment. Disposal of old mattresses to landfill is a growing problem because they are non-recyclable and non-degradable. Relying on non-renewable materials also makes the UK industry increasingly vulnerable to global competition and the price of oil.
Now at last there is a sustainable alternative design, which is expected to appeal to retailers and consumers who are looking for greener, more environmentally acceptable products. Research supported by the Sustainable Technologies Initiative shows how manufacturers can eliminate the need for foam padding and filling layers composed primarily of synthetic fibres. Instead, natural fibres derived from non-food crops and recycled wool and cotton are used. Even oil-bearing herb fibres such as lavender, long held to promote sleep, could be incorporated.
‘Our research is designed to give UK mattress manufacturers a strong technical lead, improve competitiveness through lower costs and make for more environmentally friendly products,’ says David Mulligan, Director of Manufacturing Development of Edward Clay & Son Ltd, who led the STI MATTCOMP project. ‘As a result of STI support we have been able to establish a UK manufacturing supply chain to bring the new mattress from concept to market.
The Yorkshire-based firm, a leading producer of fillings for the bedding industry, was joined in the project by a consortium of commercial and academic partners – bed manufacturers Jay-Be Ltd, Huntsman Surface Sciences UK Ltd, James Robinson Fibres, the Furniture Industry Research Association (FIRA) and scientists from the Non Wovens Research Group at the University of Leeds.
The project was supported by the DTI (now DBERR) through the Sustainable Technologies Initiative, a programme to improve the sustainability of UK business. STI research aims to achieve economic growth and employment while safeguarding the environment and conserving natural resources
The research team investigated how a novel mattress design could incorporate a far greater proportion of natural fibres. The layers of fillings in most conventional mattresses are composed predominantly of synthetic materials. Pads are arranged over the springs or alternative supports such as foam, air or water. Although some filling layers contain a proportion of wool-rich blends or other natural fibres these are normally quite thin and synthetic materials predominate.
‘It’s a very traditional industry and the design of most mattresses has changed little in many years,’ says Mr Mulligan. ‘Construction is often unnecessarily complex, raising costs. We set out to improve environmental sustainability whilst using industrially practicable processes and developing cost effective engineering solutions. Our aim was to improve the design and construction of mattresses to increase their environmental sustainability without sacrificing comfort or functionality.’
The results make it possible to apply sustainable technology to mattress production in a way that promises to benefit manufacturers, consumers and the environment. As well as minimising the use of non-renewable resources the eco-friendly design could alleviate the environmental impact of discarded mattresses, which would no longer have to go into landfill. Future products could even give consumers the option of extending the life of their mattress by replacing the filling layers.
The researchers demonstrated that going green does not mean sacrificing a good night’s sleep. The eco-friendly mattress performs just as well as benchmark products in comparative sleep tests and fire resistance tests.
With competitive pricing, the appeal of natural materials is expected to generate considerable interest in the commercial market. A UK manufacturing supply chain has been set up and the first eco-friendly mattresses are expected to be on sale at the NEC Furniture Show in January 2008.
‘Retailers recognise that green issues have come to the fore and we believe they will all want to offer an eco-friendly mattress alternative to the consumer,’ says Mr Mulligan. ‘The potential sales are substantial as research shows that most consumers would buy an eco-friendly product that meets their needs. We have succeeded in combining the “feel-good” factor that consumers like with the “sleep well” factor that they demand.’
Significant interest is also expected in the contract as well as domestic sector. Organisations that are committed to corporate responsibility are giving greater priority to environmental issues. In the prison and medical services there is increasing concern about the disposal of mattresses to landfill.
Commercial opportunities for the eco-friendly design are already foreseen in other sectors. Future applications could include other types of upholstered furniture and seating, ranging from domestic sofas and chairs to seats in the automotive, aerospace and other transport industries.