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.<\/p>\n\n\n\n
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<\/strong>, ABNT<\/strong>, and ASTM<\/strong>, depending on the final product’s requirements.<\/p>\n\n\n\n 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.<\/p>\n\n\n\n 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.<\/p>\n\n\n\n