Senior Architectural Systems, one of the UK’s largest manufacturers of aluminium fenestration solutions, is set to introduce a new waste reduction initiative as part of its commitment to circularity and working towards a fully closed-loop recycling process.
The new initiative will see all polyurethane foam waste generated during the manufacture of the patented thermal break in Senior’s low U-value PURe® aluminium windows and doors collected and reused.
Each year, approximately 80 tonnes of polyurethane foam waste is produced as part of the PURe® manufacturing process. This occurs when extra polyols and isocyanate chemicals are injected into the thermal breaks to prevent cold spots during curing. The result is a unique thermal barrier that delivers lower U-values and improved energy performance compared to traditional systems.
However, the process also creates excess cured foam and although this waste has always had the potential to be reused, it has previously been difficult to manage at scale. Senior is now working with a specialist waste partner to chemically break down the expanded and cured polyurethane foam into its original raw components—polyols and isocyanates. These recovered materials will be reintroduced into Senior’s own manufacturing processes, creating a circular system that eliminates landfill disposal.
The initiative is scheduled to be fully operational by the end of the year and once implemented, the recovered materials from the manufacture of Senior’s PURe® windows and doors will be reused internally. This approach is expected to reduce carbon emissions, cut waste, and lessen demand for virgin raw materials.
Available in a variety of configurations, including aluminium casement windows, tilt and turn windows, and both commercial and domestic style doors, the patented PURe® system has been used across the sectors, specifically in the education and residential markets.
Senior’s investment in advanced recycling initiatives builds on the company’s ongoing commitment to reducing the environmental impact of its operations and supporting customers to make more informed choices. Recent projects completed under the guidance of Senior’s dedicated UK sustainability lead Luke Osborne, include the wider use of UK sourced recycled aluminium through the company’s ReAL 2.0 product line and, most recently, the publication of a new generation of Environmental Product Declaration (EPD) documents.
Developed in line with the latest Product Category Rules, these EPDs go beyond the industry norm by providing project-relevant data across the full system, supported by scaling tables for accuracy. Unlike some comparable EPDs, which include elements outside of a system house’s supply and risk distorting results when divided down, Senior’s approach ensures complete transparency by focusing solely on the products it supplies. The first of these detailed, product-specific EPDs covers Senior’s popular SF52 aluminium curtain wall system and is available now on request or via NBS Source.
For more information, please visit www.seniorarchitectural.co.ukor search for Senior Architectural Systems on LinkedIn, Instagram and Facebook.
