Senior Architectural Recycled Aluminum Door and Window Manufacturing Waste Polyurethane Foam

Senior Architectural Systems, a leading UK manufacturer of aluminum doors and windows solutions, is set to launch a new waste reduction initiative to fulfill its commitment to recycling and strive towards achieving a fully closed-loop recycling process.

The new program will comprehensively recycle and reuse the polyurethane foam waste generated during the production of low U-value PURe® aluminum doors and windows by Senior Architectural Systems.

In the manufacturing process of PURe® aluminum doors and windows, approximately 80 tons of polyurethane foam waste are generated each year. This waste comes from the processing of thermal break strips—additional polyol and isocyanate must be injected to prevent cold spots during the curing process, ultimately forming a new type of insulation barrier with a lower U-value and better insulation performance.

However, this process also generates excess cured polyurethane foam. Although this waste has the potential for reuse, large-scale processing always faces technical bottlenecks. Currently, Senior Architectural Systems is collaborating with a specialized waste management partner to chemically decompose the cured polyurethane foam back into its original components—polyols and isocyanates. These recycled materials will be reused in their production process, creating a circular system that avoids landfill.

The plan is expected to be fully operational by the end of this year. Once implemented, the polyurethane foam materials recycled during the production of PURe® aluminum doors and windows by Senior Architectural Systems will be reused internally by the company. This approach is expected to reduce carbon emissions, minimize waste, and decrease the demand for virgin raw materials.

The patented PURe® window and door system offers various configurations, including aluminum casement windows, tilt-and-turn windows, as well as commercial and residential doors. It has been widely used across various industries, particularly in the education and residential markets.

Senior Architectural Systems' investment in advanced recycling programs reflects the company's ongoing commitment to reducing the environmental impact of its operations and supporting customers in making more informed choices.