Covestro's Polyurethane Elastomer Vision: Performance and Sustainability

Report: Murat Soygür

Polyurethane elastomers extend product service life and reduce resource consumption through their wear resistance and durable structures, while offering significant sustainability advantages through their potential to be produced from recyclable and bio-based raw materials. In the report we conducted, Covestro Elastomers Regional Sales Manager Guillaume Bizard shared detailed information with our readers about the application areas of polyurethane elastomers, the advantages they offer to users, and Covestro's position in the elastomer market.

Could you briefly tell us about yourself and your professional background?
I joined the company approximately 20 years ago. After receiving education in chemistry, I began my career as a technical engineer; during this period I provided training to customers by leveraging my expertise in both dosing machines and cast polyurethane systems, supported workshop operators, and resolved issues in production processes. After 15 years, I transitioned to the sales manager position. Based on the experience I have gained, today I am responsible for developing cast polyurethane solutions across Turkey, Maghreb countries, and South Africa, and I continue this role while placing customer-focused approach at the forefront.

How do you assess Covestro's position in the global elastomer market? How does the elastomer segment contribute to the company's overall strategic objectives?
Covestro is one of the market leaders in the global elastomer segment, strengthened by brands such as Vulkollan®, which is a reference point built on decades of innovation in high-performance cast polyurethane, and Baulé®, recognized as a reference in casting machine technology. Covestro Elastomers, which combines expertise in chemical systems and process machines, has the distinction of being the only source capable of offering customers a unique, fully integrated solution. 

Through circular economy initiatives and efforts to increase global production capacity, the Elastomers business unit makes Covestro's sustainability and innovation commitment concrete; while also contributing to growth targets and advancing climate neutrality objectives. 

Which industries currently constitute the most important application areas for Covestro's polyurethane elastomer solutions?
Covestro's polyurethane elastomer solutions currently serve three main sectors showing growth potential: 

In mines and quarries, cast polyurethane's exceptional wear resistance makes it ideal for demanding equipment such as screens, scrapers and hydrocyclones, reducing operating costs. 

In material handling, Vulkollan®-based systems deliver superior performance for wheels and rollers used in forklifts and automatic guided vehicles, enabling efficient and automated logistics operations. 

In offshore energy, Covestro's elastomers protect critical subsea infrastructure through bend stiffener and bend restrictor applications, providing resistance to demanding mechanical and environmental conditions. 

What performance advantages do polyurethane elastomers offer compared to alternative materials?
Polyurethane elastomers offer superior mechanical and dynamic performance compared to rubber, steel or conventional plastics in various applications. Wear resistance is one of the most important properties; cast PU exhibits significantly higher wear resistance compared to rubber, extending service life and reducing downtime. In terms of resistance to heat accumulation, cast PU elastomers maintain mechanical integrity under dynamic and thermal loads, providing consistent performance in demanding conditions.
Beyond performance, cast PU is easy and fast to process. This processing efficiency, combined with superior durability, provides an attractive total cost of ownership throughout the entire value chain. 

From a product lifecycle perspective, how can the sustainability contributions of polyurethane elastomers be evaluated?
Evaluating the sustainability of cast polyurethane elastomers requires a holistic lifecycle approach encompassing three stages.

In the production stage, Covestro reduces carbon footprint without compromising performance by offering mass-balanced systems verified with ISCC Plus certification, where fossil raw materials are replaced with bio-based or recycled alternatives.

In the use stage, the exceptional durability of PU elastomers contributes to sustainability by reducing the frequency of part replacement.

At the end of the lifecycle, mechanical recycling is highlighted as the first option; however, this method is generally limited to downcycling. This circular approach is transforming into concrete product innovations such as All Recyclable Mining Screen. In chemical recycling, a more advanced solution, Covestro's pilot facility in Leverkusen can break down Vulkollan®-based elastomers back into chemical building blocks without performance loss and reduce carbon footprint by up to half compared to virgin material, providing a true circular solution for high-performance elastomers. 

What are your expectations regarding the development of the polyurethane elastomer market over the next five to ten years?
Over the next five to ten years, the outlook for cast polyurethane elastomers is quite exciting. Demand in key segments such as material handling, mines and quarries, and offshore energy will be driven by automation, ore requirements and global energy transition. However, the element that truly shapes our long-term vision is our belief that the potential of PU elastomers has not yet been fully discovered. Continuous performance improvements are opening doors to entirely new sectors and application areas. Covestro Elastomers, which can supply both chemical systems and Baulé® machine technology from a single source, sets its objective clearly: to push boundaries and expand application areas; not only developing existing markets but creating and shaping new market opportunities.