The Future of Surfboard Blanks: Polyola™ Recycling PU Foam

At Polyola, we believe that every step towards sustainability counts—especially when it comes to rethinking how surfboard blanks are made. That’s why we’ve developed our  Polyola™ recycled PU formula that delivers the performance surfers and shapers demand while significantly reducing environmental impact.

What Makes Our Recycled Polyola™ Foam Different?

Polyurethane (PU) foam is the cornerstone of modern surfboard blanks, traditionally made using two main components: polyol and isocyanate. Historically, these materials are derived entirely from fossil fuels. At Polyola, we’re challenging the status quo by integrating recycled content into both components, creating blanks with 2/3 recycled material content without compromising on quality or performance.

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The Polyol Component: 80% Recycled Materials

Our polyol formulation is designed with sustainability at its core:

• Recycled Sources: More than 80% of our polyol comes from recycled polyols derived from post-industrial packaging waste.
• Reduced Virgin Resources: The remaining content includes virgin polyol, water, and additives to maintain the highest performance standards.

By prioritizing recycled materials, we not only reduce our reliance on fossil fuels but also repurpose waste streams that would otherwise contribute to environmental degradation.

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The Isocyanate Component: MDI-Based Sustainability

The second key ingredient in PU foam, isocyanate, presents unique challenges. Here’s how we tackle them:

• MDI-Based Innovation: Our isocyanate is derived partially from benzene sourced from ISCC-certified biomass, ensuring a more sustainable approach.
• Mass Balance Allocation: Given the limited availability of fully recycled feedstock, we adopt a mass balance approach. This means the overall production process incorporates 60% recycled isocyanate, even if the final product is a blend of recycled and conventional materials.

Think of it like renewable energy in a power grid: while you might receive a mix, your purchase directly supports increased production of sustainable materials.

Why Mass Balance Matters

The mass balance approach ensures that recycled content is accounted for across the supply chain, driving market scalability while maintaining transparency. This system allows us to:

1. Support Sustainable Development: By investing in recycled content, we encourage its growth and availability.
2. Deliver High-Quality Foam: Maintain the consistent performance surfers and shapers expect from Polyola blanks.
3. Scale Sustainability: Create a pathway for a greener future without disrupting existing production capabilities.

The Result: Responsible PU Blanks for a Sustainable Future

Thanks to our innovative production methods, blanks made with Polyola™ recycled PU formula from our Partner Arctic Foam contain 2/3 recycled material content, setting a new standard in sustainability for surfboard manufacturing. But sustainability doesn’t mean compromise. Here’s why our foam is a game-changer:

• Stronger & More Durable: Our recycled PU foam offers enhanced strength and durability, extending the lifecycle of surfboards.
• Optimal Flex Retention: The foam maintains its flex properties throughout its lifespan, ensuring performance doesn’t waver.
• High Performance: Polyola blanks deliver the same precision and reliability that surfers and shapers rely on, proving that eco-friendly doesn’t mean sacrificing quality.

Ready to take the next step?
Check our distributor page to find where you can purchase our blanks or connect with us for more details.

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