One of the major challenges for companies that produce flexible foams is minimizing production process waste. One solution lies in the application of circular economy principles, reusing the scraps generated during product manufacturing to develop bonded foam blocks with high added value, using binder glue, which can be applied across various segments.
Formed by mixing foam scraps with polyurethane binder glue (pre-polymer), bonded foam blocks offer good firmness and support, meeting various national and international standards for permanent deformation, density, tear resistance, and tensile strength, as required by regulatory bodies such as INMETRO, ABNT, and ASTM, depending on the final product’s requirements.
This versatility of bonded foam ensures a wide range of applications for the material, such as block use for mattresses, wood floor underlay, tatami mats, and even technical parts for industries like the automotive sector.
The block production process begins by passing the scraps through grinders, with processing times varying depending on the product’s purpose. The next step involves inserting the resulting foam flakes into mixers, where polyurethane binder glue is added. After a mixing period, the material is poured into a mold, where it is compressed to achieve the required density. The final stage involves allowing the glue to complete its reaction, ensuring proper adhesion within the block.
This entire process can be customized to meet the specific needs of each company. Amino offers a complete range of binder glues, with particular emphasis on the AMIPOL AMG All MDI line. This is a single-component, non-expanding adhesive free of solvents in its formulation, eliminating product toxicity and hazard risks, and removing the need for special handling or storage requirements.
Beyond the technology applied in the product, Amino also provides clients with a technical team experienced in developing formulations and providing technical support to address specific customer needs. This ensures optimization for both the final product and production processes, enabling faster reaction times, productivity aligned with plant capacity, excellent adhesion to various substrates, and compliance with technical standards.
In a context of growing concerns about sustainability and production efficiency, adopting a circular economy approach in the manufacturing of flexible foams represents not only a solution for minimizing waste but also an opportunity to add value to products. Bonded foam blocks, derived from scrap reuse, demonstrate not only technical quality, meeting stringent standards, but also impressive versatility in their applications.
Our specialists are available to provide more information about the AMIPOL AMG All MDI line or any other customized solutions from Amino to support your business.
