Cold Foam

What is cold foam?

Cold foam is a versatile synthetic material used primarily in mattresses, cushions, and upholstered furniture. This open-pored foam is made from polyurethane and impresses with its point-elastic, breathable, and long-lasting properties.

Characteristic of cold foam is its irregular, coarse-pored structure, which ensures high air permeability and efficiently wicks away moisture. At the same time, the material offers excellent body support and resilience – it adapts precisely to the body and quickly returns to its original shape.

Cold foam is available in different density weights and firmness levels, allowing mattresses and upholstered furniture to be tailored to individual needs. Its allergy-friendly and odour-neutral properties also make cold foam a popular choice for the bedroom.

How is cold foam made?

Cold foam is produced from a plastic called polyurethane, which is created through a controlled foaming process.

In this so-called foaming process, water and additional foaming agents are first mixed with the two main components – polyols and isocyanates. Polyols are liquid components that act similarly to a plant-based oil. Isocyanates serve as the reaction partner and are completely converted during the reaction.

During the reaction, the individual molecular structures break apart and reorganise. Carbon dioxide is produced in the process. These CO₂ bubbles expand the volume of the foam. The entire reaction takes place at low temperatures – hence the name cold foam.

The mixture is then poured into large block moulds and the cold foam cures, retaining its elastic and dimensionally stable product properties.

In the final step, the blocks can be cut and shaped to suit the intended application.

Environmental profile of cold foam

Cold foam offers many advantages in terms of comfort – but how does the material perform in terms of its overall environmental profile?

1. Raw material sourcing

Cold foam is based on petroleum-derived raw materials and is therefore more resource-intensive than natural materials such as latex or coconut fibres. Many manufacturers are attempting to replace at least part of the synthetic content with bio-based polyols. However, these developments are still in their early stages – only a very small proportion has been substituted so far.

2. Processing and energy input

The production of cold foam requires less heat than conventional polyurethane foam, which reduces energy consumption. Nevertheless, the manufacturing process is more energy-intensive than working with purely natural materials.

Some producers use renewable energy or closed production cycles to reduce the CO₂ footprint.

3. Durability

Cold foam is considered extremely long-lasting. High-quality cold foam can maintain its supportive properties for up to ten years or more without losing firmness. Its high elasticity and resilience make it particularly well suited to heavily used furniture and sleep systems.

A further advantage: cold foam is resistant to dust mites and bacteria, which extends its hygienic service life.

4. Reusability

At the end of its service life, cold foam is theoretically recyclable – in practice, however, it is most commonly thermally recovered. While energy is generated through combustion, additional CO₂ is also released. That said, a growing number of suppliers are now reconditioning old mattresses and producing new recycled foams from them.

5. Biodegradability

In short: no, cold foam is not biodegradable – at least not in the conventional sense like wood, cotton, or linoleum.

There are three methods by which cold foam can be recovered at the end of its lifespan: thermal (incineration), mechanical, and chemical.