Sustainability is the word on everyone’s lips that will undoubtedly impact the future trajectory of many manufacturing industries, as more consumers than ever seek high-quality products that will leave only a finite lasting impact on the Earth. The foam manufacturing sector is no exception, and the sustainability and disposal of the material are becoming increasingly important topics of discussion, as the industry is expected to reach $157.63 billion by 2027.1 The most pressing environmental concerns for foam lie in the disposal of the material, as a significant proportion of waste is still sent to landfills or burnt, releasing toxic fumes. The untimely breakdown of foam from the onset of microbial growth by mold and mildew is contributing to this waste, causing it to be removed and replaced more frequently. Developing enduring foam that lasts longer can help to strike the balance between meeting record high demands and being environmentally conscious by extending the lifetime of the material and avoiding its premature disposal.

The material of choice

Foam is often chosen for its ability to provide ample cushioning, noise reduction, or even efficient energy absorbance, making it the ideal material for mattresses, flooring underlay, automotive interiors, or insulation. However, the environments in which it is used are often exposed to dirt, humidity, warmth, and moisture, and are rarely cleaned, creating the perfect storm for microbial growth.

Take an automobile seat, for example, where the exchange of multiple passengers, food debris, spillages, and the warm environment can allow microbes to flourish. It was also recently shown that car interiors can be dirtier than the average toilet seat.2 As another example, under damp conditions, engineered foam that is used for insulation within the walls of a building can succumb to microbes, including mold and mildew, generating spores that can be carried in the airflow, and developing into a problem that is hard to contain. Not only this, but some foam manufacturers are turning to ingredients that are touted as ‘greener’ to help them meet their sustainability goals, but these materials can provide a more nutritional food source for microorganisms, making the material even more habitable.

A consumer-driven market

As they grow, microorganisms can create visible staining and persistent odors, making the material fall short of its promise to provide comfort. At the same time, the everyday consumer is far more aware of the impact of microbial growth on the appearance and cleanliness of surfaces in their homes and cars, especially in light of the recent pandemic. 72 % of consumers across various sectors recently disclosed that they are concerned about their exposure to bacteria and germs on surfaces. This is creating a drive for antimicrobial technologies in various sectors, as consumers seek peace of mind from anxieties around the growth of unwanted microbes. Preventing the growth of microorganisms before irreparable damage sets in can help manufacturers to meet this consumer-driven demand for cleanliness, as well as add to the circular economy by minimizing unnecessary waste.

A new kind of product protection

Foam can be engineered with additional properties that provide product protection against early degradation – which is where antimicrobial solutions excel.

Antimicrobial technologies can be seamlessly incorporated into the chemical structure of various materials – including foam – during manufacture, so that they become an integral part of the product’s makeup. They are added directly into the liquid polyol prior to polymerization in foam manufacturing, and are compatible with existing procedures. This provides around-the-clock product protection against the growth of microorganisms and works for the duration of the material’s usable lifespan, without fading over time.

By integrating antimicrobial additives, manufacturers or converters of foam can offer consumers a material with protection that limits the production of odors, damage, and staining associated with microbes, allowing the material to last much longer. End-use consumers can also enjoy the benefits of greater peace of mind, knowing that high-touch surfaces in automobiles, homes, and businesses are protected from unwanted microbial growth, adding value at every stage.

Finding the right formula

Partnering with an antimicrobial expert is the most straightforward way to start exploring the possibilities of these technologies in foam. Companies with this expertise are adept not only at selecting the most appropriate additive, but also at finding the most efficient method to integrate it seamlessly into production lines without hampering existing procedures or disrupting the quality of the foam. Development teams can then work closely alongside the manufacturers to determine and perform the most appropriate antimicrobial efficacy testing for each product application. These companies are also experienced in navigating the complex regulatory landscape that governs the type of additive and the marketing claims that can be used to develop antimicrobial foam, depending on geographical region and the specific criteria that each product falls under.

Many manufacturers are already leading the way on this new initiative for the foam industry, from incorporating it in technical foam insulation for hospitals and educational facilities to developing antimicrobial air cabin filters for automobiles. Antimicrobial foam will also be an important topic of discussion at the up-and-coming Foam Expo North America Conference Convention 2022, where Microban International will give a talk on the benefits of antimicrobial foam in automotive applications. A seismic shift in consumer awareness of microbes following the pandemic and a push for manufacturers to turn their focus to more environmentally-friendly products will no doubt drive this movement forward, engineering foam with a new kind of product protection.

To find out more about the use of Microban® antimicrobial technology in foam, visit www.microban.com/blog/preventing-mold-and-mildew-with-antimicrobial-polyurethane-foam
References
1. Polymer Foam Market Size | Global Industry Forecast [2020-2027]. (2020). Retrieved 23 May 2022, from https://www.fortunebusinessinsights.com/industry-reports/polymer-foam-market-101698
2. What Are The Dirtiest Areas Of Our Cars? | Scrap Car Comparison. (2022). Retrieved 23 May 2022, from https://www.scrapcarcomparison.co.uk/blog/the-dirtiest-areas-of-cars/