Environmental Sustainability

VPC is conscious of the environmental impact of its products during both the manufacturing process and in the finished form. We are committed to using technologies and processes that use less energy to produce superior products with less waste and contaminants.

Our practices and processes have given VPC a safety record that is among the finest in the industry. We care about how our products are made and the safety of those making them. For example:

• We use state-of-the-art, vacuum driven carbon-scrubbing technology.

• We have developed a line of products called BioPlush™, which are made with no CFCs or fillers and contain natural bio content. Many of these products are also made from 100% recyclable materials.

We are committed to a reduction in emissions and to the prevention of pollution to air, land and water:

• We conserve transportation fuels by utilizing compression techniques to increase capacity.
• Our manufacturing sites have also upgraded heating and lighting systems to reduce energy use.
• We believe that all environmental incidents are preventable and our goal for them is zero.
• We will be well prepared for emergencies and will work with local emergency preparedness agencies to improve our processes.

We encourage all VPC’s employees to develop a mutual sense of awareness and involvement for environmental care. We will provide training, information and assistance to support their efforts.

During the manufacturing process, unused and offcut scraps are collected and recycled. Post-consumer foam products are diverted from landfills to reduce solid waste and are recycled as bonded carpet cushion. Our fibre plants also recycle plastic bottles. VPC will continue to collaborate with our suppliers and industry associations on scientific research about environmentally friendly materials and renewable feedstocks.

The VPC embraces energy-efficient technologies such as those used in Flexible Polyurethane Foam (FPF) manufacturing. Through the use of an exothermic reaction, very little energy or water is required. The manufacture of FPF uses various chemical raw materials, such as isocyanates. In their raw material state, isocyanates present a potential respiratory health hazard, but during the manufacture of FPF, any isocyanates are reacted out and do not present a hazard or risk in facility emissions or end products.

Industrial Scrap Recycling

Recycled content and recyclability are two factors that define sustainable products. Flexible polyurethane foam (FPF) products are highly recyclable. With the development of practical end-uses for scrap FPF, almost every piece of process scrap is potentially recyclable.

Bonded Polyurethane Carpet Cushion

Instead of being routed into landfills, flexible polyurethane foam scraps and recovered materials are easily recycled into useful consumer products such as bonded carpet cushion. Bonded polyurethane foam carpet cushion boasts both recycled content and recyclability. With a typical recycled content of around 90%, bonded polyurethane carpet cushion primarily uses scrap foam generated from various manufacturing processes and recovered post-consumer waste from the “take up” of old product, including mattresses and carpet cushion.

Sustainable Raw Materials

In the last decade, suppliers to the FPF industry pioneered bio-content raw materials, and VPC has embraced these. Polyols derived from renewable plants such as soy and castor beans yield foams with property improvements. These improvements include better resistance to yellowing and slightly better mechanical properties such as support factor and dynamic flex fatigue.

Up to 80% of our fibre products are made from regenerated polyester staple fibres. Environmentally friendly, cost-effective, and safe, the regenerated polyester fibre is made from recycled plastic water bottles and performs as well as 100% virgin polyester.

1. Recycled polyester doesn’t require new petroleum to create, lowering the demand for new petroleum extraction and reducing the overall carbon footprint.
2. Producing recycled polyester is better for the climate, creating 75% less CO₂ emissions than virgin polyester.
3. Providing a use for post-consumer and post-industrial plastics.