The process consists in five steps:
- raw materials conditioning;
- measuring out of raw materials;
- mixing of raw materials;
- trigger reaction;
- growth verification
The three main raw materials for the production of the flexible polyurethane foam are POLYOL, TDI, and WATER. The water is the essential element for life and it is also the reagent that allows the foam to expand and to rise.
The raw materials are accurately conditioned and the different components are carried to a variable temperature between 20°C and 25°C that is the best processing temperature.
Polluting and harmful elements such as CFC and METHYLENE CHLORIDE have been banished from the process.
Raw materials, stored in tanks, are proportioned in the mixing head where the trigger reaction takes place.
Polluting and harmful elements such as CFC and METHYLENE CHLORIDE have been banished from the process. Raw materials, stored in tanks, are proportioned in the mixing head where the trigger reaction takes place. The foam goes from the mixing head to a tank or to a conveyor.
The reaction (polymerisation reaction) takes place in 1/3 minutes; during this time the foam block reaches the fixed dimensions. When the foam block gets out of the tunnel it is cut into variable length boards that are laid on the maturation system.
During the 72 hours after the production process, the polyurethane reaction ends and the boards are stored in warehouses.
After that, the product can follow two different paths: it can be cut into 2, 3, 4 mt blocks and be sold as a rough block or it can be brought in the cutting division of the company.