How it is made

From raw materials to a finished block

Eight steps of our process. The foam is made in batches, in a mould, with low-pressure mixing - the ratio of components in step two decides everything later measured on the certificate.

Raw materials
Intake and storage of raw materials: polyol, isocyanate (TDI), additives, catalysts and blowing agents.
Dosing
Precise dosing to the formulation - the ratio of components determines the block's density and hardness.
Mixing
Polyol, TDI and additives combine in the mixing head - by a low-pressure process.
Mould filling
The mix enters the mould (box) and the reaction begins - the foam starts to rise.
Expansion and curing
The exothermic reaction raises the foam to the top of the mould and it cures - this is where the cell structure forms.
Cutting and shaping
The block is cut to the required dimensions and shaped - horizontally, vertically or to contour.
Quality control
Specific weight, hardness under compression and elasticity under tension are measured - against formulation and standard.
Finished PU foam
The block is ready for further processing or delivery - cutting to size, lamination or direct assembly.

Main raw materials and additives

Polyol — base component
TDI — isocyanate
Catalyst (SO) — accelerates the reaction
Additives — DEOA, silicones, stabilisers
Blowing agents — water, amines
Other — colourants, cleaning agents

Processing technology

Block processing

Once the block is done, the second half of the job begins - cutting, profiling and bonding to your drawing.

Foam production

The foundation: polyol and TDI are precisely dosed and mixed, and the exothermic reaction raises the block in the mould. Recipe control determines density, hardness and cell structure.