Summary of Bio2Foam project meeting at Vaude and Grammer

The introductory tour at Vaude’s headquarters and production facility showcased a broad range of products, from backpacks and functional clothing to outdoor equipment like tents and air mattresses, developed in line with the company’s philosophy of using sustainable materials while maintaining high qualityA common feature of many of these products is the use of polyurethane (PUR), which is Vaude's fourth most used material with an annual volume of 212 tons (2021). Many textiles are coated with PUR, while PUR foam is mainly used in backpack shoulder pads and air mattresses. Although PUR is often criticized for its end-of-life limitations, substitution options such as PET foam and natural fibers currently cannot match PUR’s superior comfort, ergonomics, performance, durability, low weight, and compressive strength. As a result, the focus is not on replacing PUR foam but on improving its sustainability. Given the need for sustainable, non-fossil-based resources and transparent value chains, Vaude would benefit from bio-based precursors to develop a more environmentally friendly and innovative PUR foam - and potentially PUR coatings in the future.

Grammer mainly develops and produces center consoles, headrests, and high-end seats for on- and off-road vehicles, including passenger cars and commercial vehicles. Guided by legal regulations and customer-driven industry standards, Grammer must continuously adapt to evolving requirements. Circularity, particularly recyclability, is currently a key focus in the industry, leading to complex demands regarding sustainability, performance, and safety. PUR foam is one of Grammer’s primary materials, with an annual volume of 7,000 to 10,000 tonnes, that must meet these high standards. For example, headrests made from foam need to be flexible, which requires polyols with specific chain lengths and involves several emission and performance tests. Grammer has the technological capabilities and expertise to produce and test foams and to supply Vaude with materials for prototype development.

The IKK delegation gained valuable insights into production processes at Vaude and Grammer, which will help model the relevant processes for a Life Cycle Assessment (LCA). The IKK also gained a better understanding of their partners' situations, the requirements of their products, and their key priorities. The introduction of other potential foam materials will allow comparisons with the foam to be developed in the Bio2Foam project, helping to identify potential benefits and challenges of the new material. It also became clear that transparent and accurate communication of environmental impacts is a key factor. In addition to the sustainability assessment, the opportunities for testing the new material were discussed, which will assist in preparing and evaluating the testing capabilities at IKK, creating synergy effects with Grammer. Further exchanges on this are already planned.

At the end of the project meeting, the next steps for advancing product development were discussed. Once Vaude communicates their material requirements to Grammer, following internal consultations, Grammer will define the characteristics of the bio-polyol. In close collaboration with Grammer, Lextra, and QUT, the required properties of the bio-polyol will be defined to guide the functionalization of the crude polyol supplied by Licella. Small quantities of the bio-polyol will then be sent to Grammer, where the first foam parts will be manually produced and tested in cooperation with IKK. Based on the results, the foam formulation, as well as the polyol production and functionalization, can be optimized before larger quantities of the bio-polyol are processed into first prototypes. Meanwhile, a screening LCA tool will be developed to help assess the potential environmental impacts of different formulations, supporting the integration of sustainability into product development.

The short project meeting highlighted that, despite coming from different industries, the challenges faced are quite similar, and there is a shared interest in each other’s success. Three days of joint discussions on equal footing significantly boosted the motivation to develop a sustainable, bio-based material through international collaboration that could help transform the industry. The anticipation of further collaboration with Licella, Lextra, and QUT has also grown. The upcoming project meeting in Australia, currently being planned, is expected to be one of the next key milestones of the Bio2Foam project. The German industry and academic project members are looking forward to the visit and are excited about continuing the exchange to get to know each other better, to learn from each other, and to support each other in realizing the mission of Bio2Foam and the individual goals of each partner.