The young Spanish company Bõln uses an innovative bio-based polyurethane material in the design of its products. The versatile, modular furniture and elements are made from 90% plant waste, demonstrating the potential for circularity and functionality in furniture production.
by Kathrin Spohr
Bõln – the name sounds almost German. Were it not for the Spanish tilde hovering over the ‘o’. Bõln is a coined term. Short and catchy, it makes for a memorable brand name. And it makes sense: Bõln is a young company from Zaragoza, Spain, that is shaking up the market by manufacturing furniture from a self-developed material made from plant waste called Flexyskin. Not only because Bõln is a prime example of the possibilities of green technologies, but also because Flexyskin is a high-performance material that meets even the highest demands for public outdoor furniture. The brand’s modern, simple design is also impressive: it’s colourful, comfortable, soft, modular, versatile and round.
Expertise and Pioneering Spirit
In 2020, engineer Fernando Rivas launched the Bõln brand, drawing on the experience and knowledge of his father’s company, Poliuretanos Rivas, where the now 49-year-old started as production manager after graduating. Poliuretanos Rivas is a renowned Spanish manufacturer that has specialised in the production of polyurethane foam components for over 40 years. It’s no surprise that the history of this young Spanish brand begins with an innovative material: Flexyskin, an eco-friendly polyurethane foam made from green waste. “We were looking for a polyurethane-related material that could be used outdoors and in heavy-duty applications,” explains Fernando Rivas. “The technical development took five years. When we realised that Flexyskin was robust enough and met our expectations, we decided to launch Bõln – even though the Covid pandemic was having a huge impact on all our lives at the time”.
Nordic Simplicity Meets Mediterranean Vibrancy
Indoor and outdoor, as a single piece or as part of an ensemble, as an interior object or as a simple add-on. It’s this simplicity, underpinned by a progressive philosophy, that makes the company and its products so remarkable. Or as Fernando Rivas puts it: ‘Bõln combines the simplicity of Nordic design with Spanish passion, liveliness and soul’. He hits the nail on the head, as the furniture is created in collaboration with internationally acclaimed design studios from Sweden and Spain: Studio Mattias Stenberg from Stockholm, Stone Designs from Madrid and Nacar Design from Barcelona. Seven collections – including one specifically for children – have been launched since 2020, bringing a climate-friendly future to public and community spaces around the world.
‘Flexyskin is a flexible polyurethane based on biomass. Basically, three components come together: a bio-based soft foam, an outer membrane and a colour.’
– Fernando Rivas, Bõln
Flexyskin combines numerous qualities: it can be produced industrially, is weather and water resistant, soft, warm and has an antifungal and antibacterial surface | © Bõln
Advanced Material Technology
Flexyskin is a milestone in sustainability: Its production transforms plant waste – a CO2-neutral, previously under-utilised raw material – into a high-quality, versatile material. Flexyskin not only reduces dependence on oil, but also contributes to a circular economy. ‘Flexyskin is a flexible polyurethane based on biomass. Basically, three components come together: a bio-based soft foam, an outer membrane and a colour. They are all polyurethanes. The foam is sustainable and recyclable, while the other two components make up only 10% of the final product. The paint is a thin, effective coating. As a result, our final product is 90% plant waste’, explains Rivas.
But as simple as the material’s composition sounds, Flexyskin is the result of years of research and development. The challenge was to combine biological raw materials with modern materials technology to create a product that is both sustainable and meets the highest functional requirements in terms of durability, flexibility and resistance.
Soft on the Inside, Hard on the Outside
Plant waste itself poses a particular challenge: its chemical composition is heterogeneous and very diverse. Differences in fibre, cellulose and lignin content, as well as potential contaminants, make consistent processing difficult. Innovative methods were needed to treat these raw materials so that they would reliably exhibit the desired properties such as elasticity, flexibility and durability. ‘The biggest challenge, however, was to achieve the softness required for outdoor seating’, says Fernando Rivas. Binders are needed to turn plant waste into a malleable and durable material. The key was to find an environmentally friendly binder that was free of synthetic chemicals and yet improved the mechanical properties. Balancing science, technology and sustainability. The plant-based raw material – corn starch, sugar cane bagasse or cellulose from wood waste – is sourced exclusively from certified, renewable sources in the German chemical industry. ‘It is guaranteed that no plants have been grown specifically for the production of the waste’, stresses Rivas.
A Real Alternative, a Powerful All-Rounder
The market innovation of Flexyskin lies in the successful transformation of waste materials into a high-performance product. It can be manufactured and processed industrially and can easily compete with conventional foams. Despite its robust appearance, the foam is soft and malleable, offering maximum seating comfort. It is non-flammable, has anti-bacterial and anti-fungal surfaces and is weather and water resistant. Conventional PA foam is also durable and malleable, but its main drawback is that it’s difficult to recycle. When you consider that the global market for polyurethane foam is expected to grow by 6.9% annually through 2032, according to Fortune Business Insights, the importance of Flexyskin in the fight against climate change becomes even clearer: ‘Since we launched the material, we’ve been inundated with enquiries from various industries! We are already working on a number of new products for third parties’, says Rivas.
Scalable Furniture
Bõln’s softly rounded furniture and modules are a progressive response to today’s needs for modern, shared environments. They fit seamlessly into casual, informal spaces as well as demanding architectural settings. Each setting can be customised at any time with different colour options and accessories such as panels, tables and workstations. The versatile dimensions of Bõln’s furniture are expressed in a collection by Swedish designer Mattias Stenberg: His colourful VISTAS collection elements are designed to create a variety of seating structures and arrangements – freestanding, in rows or in a 360° configuration. The modules can be placed on the floor, on slender legs or on a platform. These options allow you to create either fluid and casual or sculptural and permanent looks.
‘Our goal was to create a material that could adapt optimally to modern needs. Sustainable, versatile and playful at the same time.’
– Fernando Rivas, Bõln
Customisable Seating Comfort
What’s next for Bõln? Fernando Rivas: ‘More sustainability! We’re working on an action plan to continuously improve all departments and products. This includes new internal procedures to replace fossil materials and reduce energy consumption in the company, for example by increasing the use of solar panels and using more efficient moulds. Our new products will be introduced with an even greater focus on sustainable design’.
What may sound complex in theory can be strikingly minimalist in practice, while offering maximum functional versatility. Take, for example, Stone Designs’ SLIM seat cushion, recently launched at Orgatec 2024 in Cologne. The seating collection is based around a small Flexyskin element, either as an individual ergonomic seat attached to benches and stools, or as a floor or grandstand cushion – SLIM connects with existing furniture or architecture to create soft seating options for permanent or temporary spaces.
‘Our goal was to create a material that could adapt optimally to modern needs. Sustainable, versatile and playful at the same time. And because of its rounded shapes, the furniture is also perfect for children or the elderly’, comments Fernando Rivas. ‘In short, we’re working towards a softer world!’
Share on Social Media
