Continuous machine foaming using raw material throughputs of 100 to 300kg/min.

These processes include:

• Conventional crown-block process                                                                          
• Draka and Petzetakis processes                                                                                
• Hennecke and Planiblock processes                                                                         
• Maxfoam process                                                                                                         
• Varimax process
• Round-Block Process
• Vertifoam process                                                                                                    

The processes listed are basically similar excluding Vertifoam which produces foam vertically instead of horizontally, for space saving. The other processes are improvements derived from each other. The most recent processes used are the Varimax Process and the Vertifoam Process. The Round-Block process is similar to the Varimax process except round blocks are poured rather than the conventional square blocks. This is to create less cutting scrap during conversion of the block by a peeling machine.

Currently a new process has been design by Canon-Vicking which uses CO2 as an alternative blowing agent, which can hooked up to the Varimax process mentioned above.

Commercial box foaming for quantities between 5 and 100kg.

This gives the advantage of :

in-house production of foam, or versatility in making different types of foam. Single block foaming is financially cheaper than continuous foam production and enables you better latitude in producing different grades.

The bun sizes are usually similar to the ones cut off from Slab stock.

Moulding:

Moulding provides parts for the market that requires particular shapes and sizes. Foam moulding involves pouring an appropriate polyurethane urethane mixture into a suitably shaped mould. The mould is then closed (if necessary), allowing the mixture to expand and fill the mould cavity.

This area of the industry is a very specific one and changes from company to company. A systematic approach should taken in creating a moulding process. PUTech is confident and quite capable in assisting in any facet of this process.