Transforming Waste: Turning Old Mattresses into High-Performance Insulation

At the Australian Bedding Stewardship Council (ABSC), our mission is clear: to drive circularity within the bedding industry and keep mattresses out of landfill. While we have made great strides in recycling steel springs, the “soft parts” of a mattress – the foam and textiles – have historically been much harder to recover. Approximately 56% of mattresses collected for recycling are mechanically shredded, resulting in a complex mix of materials known as “floc” that currently lacks an off-take market.

In partnership with Swinburne University of Technology, we are excited to share a breakthrough. Together, we are pioneering a way to turn this difficult waste into a valuable, sustainable building material.

The Science: Nature’s Own Recycler

Led by Dr. Peter Nguyen with commercial guidance from our Director of Innovation, Tracey Pryor, this project uses a unique biological process to upcycle mattress shred. Using a specific fungus, Penicillium chrysogenum, the research team grows a natural mycelium binder that “eats” and binds together shredded mattress foam and textiles. The result is a lightweight, fire-resistant insulation material that performs as well as traditional commercial products.

Why This Matters for Circularity

This innovation has potential to solve one of the key material challenges with mattress resource recovery:

Diverting Waste: Over 1.8 million mattresses are discarded in Australia every year. This technology gives their components a second life in our homes and offices.

Fire Safety & Performance: The process naturally creates mineral compounds that resist extreme heat, remaining stable at temperatures near 1000°C.

Low Carbon Footprint: Unlike energy-intensive mineral wool or foam, these bio-composites use a low-emission, natural growth process.

Funding Innovation and Global Partnerships

Our Director of Innovation, Tracey Pryor, in partnership with the research team at Swinburne University of Technology, is actively pursuing diverse funding streams to bridge the critical gap in mattress shred off-take markets. This effort includes securing vital in-kind and financial commitments from ABSC members and industry partners.

Beyond Australia, we are fostering international alliances to refine this technology and its industrial processing. Our CEO, Kylie Roberts-Frost, recently showcased these advancements at the International Sleep Products Association (ISPA) EXPO in Orlando, engaging with global collaborators and exploring funding pathways through organisations like the Mattress Recycling Council in the US.

To transition this breakthrough from the lab to the marketplace, we have applied for the Australian Government’s Australia’s Economic Accelerator (AEA) Ignite grant. This competitive funding is essential for the next phase of development:

Refining the Process: Optimising fungal bioconversion to handle the high variability of real-world polyurethane foam and textile waste.

Scaling Up: Moving from 50g laboratory batches to pilot-scale production in coordination with our industry partners, Repurpose Recycling and Four Seasons Industries.

Attracting Investment: Lifting the Technology Readiness Level (TRL) to attract investment from industry to further develop the commercialisation of the product.

This multi-pronged approach to funding and partnership ensures the ABSC remains at the forefront of circular innovation, turning a significant waste challenge into a sustainable sovereign manufacturing opportunity.

Driving the Remit Forward

This project is a cornerstone of our remit from the government to create a truly circular economy for bedding. By investing in R&D and securing major grants like AEA Ignite, we are ensuring that the Australian bedding industry stays at the forefront of global sustainability. Success here could be game-changing, with potential applications for other difficult waste streams like carpets and mixed clothing textiles.

“Our work shows how science and industry can come together to turn difficult waste into something useful, safe, and sustainable.” – Dr. Peter Nguyen, Swinburne University of Technology

We look forward to keeping our members updated as we move toward a future where no mattress part is ever waste.

Read the full article published in Nature by Swinburne: https://www.nature.com/articles/s41598-025-30954-x