Stahl Launches PermUCell™ Technology to Accelerate Sustainable Polyurethane Material Production

Speciality coatings company Stahl has introduced PermUCell™, a market-ready technology designed to enable more sustainable production of polyurethane (PU) materials by replacing conventional solvent-based coagulation processes with a fully water-based alternative. The technology addresses growing environmental and regulatory concerns associated with the use of dimethylformamide (DMF), a hazardous solvent widely used in the production of PU-coated textiles and synthetic leather.

DMF is subject to increasingly strict regulations, particularly under European chemical legislation such as REACH, prompting the industry to seek safer and lower-impact manufacturing routes. PermUCell™ offers a 100% water-based coagulation process, eliminating the need for harmful solvents while still delivering the performance characteristics required for high-quality PU substrates.

According to Stahl, the technology produces coatings with the same porous structure, softness, flexibility and breathability typically achieved with traditional solvent-based processes, ensuring that sustainability improvements do not compromise product performance. Importantly, the system is designed to be compatible with existing production infrastructure, allowing manufacturers to adopt the new process without major capital investment or significant changes to established coagulation lines.

In addition to removing DMF from the production process, PermUCell™ can also reduce water consumption by up to 70%, further lowering the environmental footprint of PU-based materials. The technology aligns with broader industry initiatives such as the Zero Discharge of Hazardous Chemicals (ZDHC) programme and supports compliance with stricter chemical safety standards. Stahl emphasises that the solution is already available as an off-the-shelf, industrial-scale option, enabling manufacturers to transition rapidly towards cleaner production methods.

The innovation is particularly relevant for industries that rely heavily on PU-coated fabrics, including footwear, fashion accessories, apparel and home furnishings. By combining sustainability, regulatory compliance and performance parity with conventional materials, PermUCell™ aims to accelerate the shift toward more responsible polyurethane production while supporting brands and manufacturers seeking to reduce the environmental impact of flexible materials used in consumer goods.

Source: Stahl