Just like other industries produce by-products like sawdust, oils, ash, and feathers, foam conversion generates foam offcuts. In today’s modern age, sustainability is crucial and recycling is more important than ever. However, foam, being oil and chemical-based, is not considered environmentally friendly. So, how can we address this issue?

One major concern in foam cushion manufacturing is the significant amount of waste produced when cutting the cushions from foam blocks. Foam blocks are typically 2m x 2m x 1m in size, which are then split into sheets and cut into customer-specific cushion sizes. This process often results in odd-shaped pieces that are too small to be used as cushion pads. While these small foam pieces can be bonded together to form larger usable pieces, customers generally prefer to avoid any joins in their foam cushions, except in cases where cushion sizes exceed the size of foam blocks.

At Direct Foam, we are focused on repurposing all our foam offcuts that are produced in the factory to prevent them from ending up in landfills. Every scrap of foam we create is utilised.

All of our foam offcuts are recycled. We collect all the offcuts and put them into a baling machine which granulates and bonds the pieces of foam together, then compresses it into blocks to produce our recycled or reconstituted foam. This type of firm foam is a perfect choice when you need a budget foam. We produce four grades of reconstituted foam:

• Blue/Green 4lb, density 64 kg/m3 recycled foam – used for various furniture applications
• Yellow 5lb, density 80kg/m3 recycled foam – used for seating and various furniture applications
• Orange 6lb, density 96 kg/m3 recycled foam – Heavy duty recycled foam used mainly for bar and restaurant seating
• Yellow 8lb, density 128kg/m3 recycled foam – Extremely heavy duty and very firm. Used for crash mats and firm seating.

If you would like to learn more about our environmental policy, please call us on 01293 871712 and will be happy to answer any questions you may have.

The post How we recycle our foam offcuts appeared first on Direct Foam.

The cushions on your favourite sofa don’t last forever, so when they start to wear out, or are not as comfortable as they once were, it doesn’t mean you have to buy a brand new sofa.

Older sofas are usually made from higher quality materials, which can often last much longer than some newer, cheaper sofas. If your sofa frame is in good condition, then consider investing in sofa cushion replacement.

Whether you’re looking to save money, refresh your old sofa, add some extra comfort, or wish to be more environmentally friendly, then refilling your seat cushions with new foam is the answer.

Here are some of the benefits of choosing a sofa cushion replacement service:

Lifespan

Replacing cushions when needed can extend the life of your sofa, saving you money in the long run. In addition, finding the perfect sofa can take time, with many things to consider before investing in your ideal sofa. These can include size, style, comfort and ultimately price. Replacing the cushion foam in your sofa will save you time and stress.

Comfort

Sofa cushions can lose their shape over time, especially with daily use, which will affect the comfort of your sofa. Replacing sofa cushions can breathe life back into your sofa, ensuring optimal comfort for years to come.

Appearance

Daily use can affect the appearance of your sofa over time. Give your sofa a new look and feel with sofa cushion replacement. By simply replacing the foam inside your sofa cushions, you can restore its appeal.

Sustainable

Did you know that only 17% of sofas get recycled? With over 4.2 million sofas discarded every year in the UK, landfill waste is a real problem for the environment. However, if you opt for replacement sofa cushions, for every tonne of sofas we refurbish, we will help save 1.5 tonnes of CO2 emissions.

This is a much more sustainable option and will help reduce landfill waste.

Sofa cushion replacement is easy!

Our sofa cushion replacement service is your hassle-free way of replacing you’re old and worn out sofa cushions!

All you need to do is order one of our collection packs or call us on 01293 224096 to request one (our collection packs are sent to you free of charge). When it arrives follow the instructions provided and securely package up your sofa cushions (we only require the covers). Contact us to arrange for them to be collected. We’ll then send a courier to you on the weekday of your choice to deliver your replacement sofa cushions.

Photo by Tolga Ahmetler on Unsplash

The post 4 reasons why you should invest in sofa cushion replacement appeared first on Direct Foam.