Even if some conversations around sustainability have cooled in the face of corporate greenwashing and macroeconomic pressures, meaningful recycling and upcycling projects are emerging in aircraft interiors and deserve attention.
Take, for instance, the new GENCYCLE+ circular economy solution from New Zealand-headquartered Generation Global (GEN), which specializes in aircraft seat covers, cushions and interior soft goods.
Unveiled for the first time at the Aircraft Interiors Expo in Hamburg, GENCYCLE+ is designed to ensure that aircraft seat covers and cushions never go into landfill. The process sees old interiors converted into recycled raw materials and remanufactured into new GENCYCLE+ products.
How does it work?
“Airlines decide they want to do a refurbishment program due to re-branding, refresh updates, etc. They will then strip the old soft furnishing covers and cushions from their aircraft. This can include all elements from dress covers (both natural and synthetic leathers), cushions, velcro, fireblocker, etc, and can be from any existing livery, not just GEN’s product. No hard plastic, composite, or metals can be sent back in,” GEN vice president, global sales Jared Steyaert explained to Runway Girl Network.
He continued:
GEN arranges for pickup and transport to a parter recycling facility. The used products and parts are then processed and turned into a raw fibre material that is then compressed and formed into new foam blocks that then get cut and shaped to be used for backrest and headrest cushions as new products to meet whatever spec, comfort, and shape the airline needs for their project.
These new foam blocks can be engineered and manufactured to have a wide range of densities, exactly like standard commercially used PU or graphite foams would. These various densities can be used to then make new backrest and headrest cushions are needed for the airline’s refurbishment needs.
According to the firm, the cushions can be certified as standard aircraft backrest and headrest cushions, and their lifecycle is the same as that of traditional cushions. Once the lifecycle is exhausted, GEN engages with the airline to send the used cushions back for continued recycling.
Generation Global has positioned GENCYCLE+ as cost neutral, as the cost of recycling and remanufacturing “is balanced against the cost of producing new cushions, with no additional expense to the airline.”
And, since the products are responsibly recovered and repurposed, and placed back into productive use, the unnecessary CO₂ emissions associated with disposal and replacement can also be avoided.
With several global locations, including in the United States and Malaysia, the company already supports airlines, OEMs and seating manufacturers with certified solutions focused on comfort, durability and innovation.
As such, it believes the GENCYCLE+ program can integrate seamlessly into existing supply and maintenance processes, providing a “realistic solution for operators seeking to move beyond sustainability statements toward tangible environmental outcomes.”
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All images credited to Generation Global
