Our client, a Spanish window manufacturer, wanted to eliminate its dependence on petroleum-based polyurethane foam. As project manager, I coordinated a four-person team to validate alternative feedstocks, assess production feasibility, and build a recycling loop that would keep materials in use.
Finding the Right Material Science Backbone
I combed through academic research to locate a proven process that upgrades used cooking oil into a polymer precursor. Matching laboratory results with industrial partners gave us the confidence to recommend the approach and highlight tolerance envelopes for scaling.
Mapping the Circular Flow
- Identified European collection partners for sourcing post-consumer cooking oil.
- Outlined processing steps, including hydrogenation and polymerisation, with suggested partners and equipment lists.
- Designed an end-of-life loop where returned window frames are mechanically recycled and reintegrated into new foam production.
Logistics & Impact
By reshoring the supply chain within Europe, we eliminated 1.5 months of shipping time from Asian suppliers and drastically reduced carbon footprint. We backed each recommendation with lead time, cost, and risk analyses so executives could phase implementation with confidence.
Skills Demonstrated
- Supply chain mapping and logistics optimisation.
- Circular economy design and life cycle analysis.
- Project management, stakeholder alignment, and technical research.