With approximately 28 million hot tubs in operation worldwide, the frequent replacement of traditional foam covers contributes significantly to environmental waste. These covers, typically made from expanded polystyrene (EPS) foam encased in vinyl, have a lifespan of 3 to 5 years and are often non-recyclable, leading to substantial landfill accumulation. At thrml.™ we understand the waste volume from these products which is one of the many reasons we created the innovative AIRCAP 1™ , to address these issues by offering a longer-lasting, more durable, environmentally friendly option to our customers.

 

Global Hot Tub Ownership and Cover Usage-

Hot tubs are a popular relaxation and therapeutic feature in homes and commercial settings globally. Estimates suggest there are around 26 to 28 million hot tubs in use worldwide, with the U.S. alone accounting for about 7.3 million. 

 

Traditional hot tub covers are essential for insulation, energy efficiency, product protection, but the dominant design uses foam cores that degrade over time due to moisture absorption, UV exposure, and chemical breakdown from spa water. These covers must be replaced every 3 to 5 years on average, with outdoor exposure accelerating wear to as little as 2 to 4 years in harsh climates

Environmental Impact of Foam Hot Tub Covers-

Foam hot tub covers pose a significant environmental challenge because they are are not recyclable. The EPS foam core often absorbs water and hazardous chemicals, becoming saturated and ineffective, while the vinyl exterior tears or fades. Many waste facilities refuse them due to the composite materials and hazardous chemicals in the foam. As a result, most end up in landfills, where they contribute to non-biodegradable waste. In North America alone, an estimated 165,000 covers are discarded monthly, exacerbating landfill overcrowding and releasing microplastics over time. Broader environmental concerns include the energy-intensive production of manufacturing new covers and the overall carbon footprint of hot tubs, which can be mitigated by better insulation but worsened by frequent replacements.

 

Calculation of Annual Landfill Waste-

To quantify the waste, we use the following assumptions based on industry data:
- Global hot tubs: 28 million (as per query premise, aligned with estimates of 26-28 million).
- Average cover lifespan: 4 years (midpoint of 3-5 years).
- Annual replacements: Total hot tubs divided by average lifespan = 28,000,000 / 4 = 7,000,000 covers per year.
- Average weight per cover: 100 pounds (based on typical ranges of 75-125 pounds for standard 7-foot square covers).

**Total annual waste weight:** 7,000,000 covers × 100 pounds = 700,000,000 pounds (or 350,000 tons, converting at 2,000 pounds per ton).

This calculation assumes steady-state replacement and does not account for market growth or variations in cover sizes/weights. In reality, waste could be higher in regions with harsher weather, where lifespans shorten to 3 years, potentially increasing annual waste to over 920 million pounds (460,000 tons).

The Sustainable Alternative-

 

The AIRCAP 1™ hot tub cover from thrml™ addresses many of these waste issues through innovative design. Made from rigid welded drop-stitch PVC—similar to that used in durable inflatable paddleboards—it easily inflates for use. Our patent pending AirLoc™ heat welded  construction makes it significantly stronger and more durable than foam covers, extending lifespan beyond the typical 3-5 years by resisting moisture, UV damage, and physical wear. Additionally, drop-stitch PVC is recyclable; PVC materials can be mechanically recycled up to 6-7 times without significant loss of properties, reducing landfill contributions compared to foam. While some PVC composites pose recycling challenges, advancements in sorting and processing make this a viable eco-friendly option. Features like our patent pending Ziptech™ zip-on replacement skirts and the ability to pressure wash further enhance longevity and ease of maintenance, significantly cutting replacement frequency and waste.

 

The thrml.™ Commitment-

 

At ​​thrml. we are committed to designing products that prioritize planetary health, aligning with growing consumer demand for sustainable wellness solutions in the hot tub market.

 

By focusing on energy efficiency, material innovation, longevity, and zero-plastic recyclable packaging, thrml.™ minimizes environmental impact across the product lifecycle—from production to end-of-life. Product Design for Environmental Benefit, thrml.'s™ flagship AIRCAP 1™ and our future products are engineered to significantly reduce the ecological footprint of hot tub ownership. Key design principles include:

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1. Superior Thermal Insulation and Energy Efficiency
   The core of The AIRCAP 1™ incorporates our advanced AirLoc™ technology to trap heat effectively. A well-insulated cover like AIRCAP 1™ can reduce heat loss by up to 50% compared to standard foam hot tub covers, meaning the hot tub heater runs less frequently. This directly lowers energy consumption—hot tubs are among the more energy-intensive home appliances—and cuts greenhouse gas emissions from electricity generation. For homeowners, this translates to lower utility bills and a smaller carbon footprint, supporting sustainable at-home wellness without compromise.

2. Durable, Long-Lasting Materials

   • Recyclable low-impact outer material which is lighter, more UV-resistant, and recyclable. A solution to dyed polyester traditional vinyl and EPS foam.

   • High-performance, welded drop stitch needing significantly less frequent replacement.

   • Avoidance of polluting elements like heavy Styrofoam.
     Longer-lasting covers mean fewer resources used in manufacturing and less landfill waste over time.

3. Water Conservation and Reduced Chemical Use
   By minimizing evaporation (a major issue with poorly insulated tubs), The AIRCAP 1™ helps maintain water levels and chemistry. This reduces the need for frequent refills and chemical treatments, conserving water and limiting the release of sanitizers into wastewater systems.

4. Overall Lifecycle Impact
   The AIRCAP™ is designed for reparability and recyclability at end-of-life, encouraging circular economy practices. Features like modular components and easy-to-replace parts extend usability, while energy savings compound environmental benefits throughout the product's life (typically 5–10+ years with proper care).

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Zero-Plastic, Fully Recyclable Packaging.

 

All thrml. packaging is designed to be 100% reusable and fully recyclable (or curbside-compatible in most U.S. locations), eliminating single-use plastics entirely:

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• Materials Used: Corrugated cardboard boxes (made from high post-consumer recycled content, often FSC-certified for responsible sourcing), paper-based protective wraps, kraft paper tape (water-activated or reinforced for strength without plastic), and recyclable paperboard inserts or honeycomb structures for cushioning.

• Benefits: This approach avoids plastic pollution, reduces fossil fuel dependency in packaging production, and supports easy recycling—cardboard and paper can often be recycled multiple times. It aligns with our zero-waste goals at thrml.™

• Implementation: Packaging is minimalist yet protective (e.g., custom-fit boxes to minimize material use and void fill), with clear recycling instructions printed on boxes to encourage proper disposal.

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By combining these elements, we not only deliver high-performance hot tub covers that save energy and money but also contribute to our broader planetary goals: lower emissions, reduced resource extraction, less waste, and promotion of sustainable outdoor living.