Walki®Soft Foam
Advanced Carriers for Foaming
Reliable, efficient, purpose-built for productivity and sustainability.
Engineered for excellence.
Trusted by leading machines
across the industry
Walki®Soft Foam solutions are advanced process carrier materials designed for reliable, efficient and sustainable soft foam production. With over 35 years of experience in the industry, Walki supports leading foam manufacturers worldwide with peelable, non-peelable and paper-based carriers that enhance surface quality, reduce chemical waste and improve productivity. From bedding to automotive seating, our purpose-built materials deliver consistent performance, cost efficiency and recyclability – helping customers achieve top-tier results with circular design in mind.
Product Overview
Walki®Soft Foam offers a complete range of advanced carrier materials designed to optimise every stage of the soft foam production process. The portfolio includes three main types: Walki®Peel Foam for a premium surface finish with a peelable film that enhances block quality, Walki®Cover Foam for cost-efficient operations with non-peelable carriers, and Walki®Paper Foam, a fully fibre-based alternative for simplified handling. Each solution is precisely engineered to suit specific temperature ranges, foam densities and machine types, including Hennecke, Laader Berg and Cannon Viking ensuring consistent performance, reduced waste and smooth, reliable production.
Walki®Peel Foam
Our most popular and versatile solution features a peelable film that remains on the foam block, significantly enhancing surface quality. Designed for compatibility with top, side and bottom layers, it adapts seamlessly to various production needs. This solution is especially effective for high-density foam and performs exceptionally well with modern equipment, making it a reliable choice across diverse applications.
Walki®Cover Foam
Walki®Cover Foam is a non-peelable carrier. Released after foaming, it ensures smooth foam block surfaces with minimal residue. Ideal for low-density foam using CO₂ expansion, it reduces chemical use, keeps machinery clean and lowers production costs. Made from PE-coated kraft paper, it offers strong stiffness and tear resistance. Perfect for bottom and side applications in setups with lower tear strength.
Walki®Paper Foam
Walki®Paper Foam is a paper-based solution without a polymer layer, where the carrier remains on the foam block after foaming. It provides basic support while helping maintain clean machinery and reduce production costs. Commonly used as a top layer to vent gases, it is suitable in applications where paper residue in off-cuts is acceptable and does not affect chemical absorption or TDI efficiency.
Choosing the right material
Selecting the right process carrier is key to achieving high foam quality and operational efficiency. Walki’s technical experts help customers match carrier strength, stiffness and peel force to their process requirements. Whether your priority is heat resistance, recyclability or surface perfection, Walki offers tailored grades such as:
Walki®Peel Foam 85 / 85H / 95 / 115H – for peelable, high-performance applications.
Walki®Cover Foam 85 / 115 – non-peelable solutions for open-side systems.
Walki®Paper Foam 85 – fully paper-based variant for simplified operations.
Why Leading Manufacturers Choose Walki®Soft Foam Solutions
Walki®Soft Foam is trusted by manufacturers across Europe, the Americas, Asia and Africa because it turns innovation into measurable value:
- Up to 3% reduction in chemical consumption, lowering total production costs.
- Uniform foam density and high-quality block surfaces.
- Reliable global supply from multiple European production sites.
- Full compliance with EUDR and REACH.
- Dedicated R&D and technical service to support custom process optimisation.
Example:
For 200,000 m³ annual foam production, Walki carriers can save up to €200,000 per year through reduced chemical waste and higher efficiency.
Walki carrier materials for foam production
Innovation in every step. Perfection in every layer.
Sustainability Focus:
Tailored Carrier Solutions with Circular Thinking in Mind
Sustainability is embedded in every Walki®Soft Foam product.
The recyclable fibre layer can be repulped in standard recycling facilities, reducing waste and raw material use.
Through optimised material design and renewable energy production, Walki helps customers achieve circular production goals by:
- Minimising chemical and material waste
- Lowering energy and resource consumption
- Replacing non-recyclable materials with recyclable or bio-based alternatives
Walki’s approach supports both economic efficiency and environmental responsibility, aligning with the transition to a circular foam industry.
Comparison with traditional solutions in the soft foam business
| Walki®Peel Foam solutions | Traditional carriers (film/composite) | |
|---|---|---|
| Chemical waste | Reduced up to 3% total savings | High, due to absorption and leaks |
| Surface finish | Smooth, uniform block density | Irregular or porous |
| Recyclability | Recyclable and reusable fibre layer | Limited or non-recyclable |
| Heat resistance | Stable up to 135 °C (H grades) | Inconsistent |
| Operational costs | Lower cost per m³ produced | Higher TCO |
Technology & Innovation Behind
Research & Development
Technical Competence Centres
At Walki’s Competence Centre, innovation meets precision. Our dedicated pilot line enables real-world testing and optimisation of Walki®Soft Foam carrier materials. This in-house capability allows us to fine-tune parameters such as peel force, stiffness and heat resistance, ensuring consistent performance across various machine types and foam densities. Through close collaboration with customers, every new grade is rigorously tested for efficiency, recyclability and quality before full-scale production — guaranteeing reliable, high-performing materials ready for industrial application.
Pioneering the future of fibre-based barrier production
Walki®Soft Foam solutions represent the next generation of fibre-based barrier materials, engineered to combine technical excellence with circular design. Produced in Europe and supported by multiple backup production sites across Central and Eastern Europe, Walki ensures secure and reliable supply for customers worldwide. Our technical development is driven by pilot line R&D, where every formulation is refined and tested for optimal process performance. With decades of expertise in soft foam carrier solutions and a strong global logistics network capable of managing complex supply chains and documentation, Walki stands as a trusted partner for manufacturers seeking high-quality, sustainable and future-ready materials.
It’s a range of carrier materials that support soft foam production – commonly used in bedding, furniture, automotive and technical foams.
Walki®Soft Foam enhances surface quality, reduces chemical waste and ensures reliable, clean and cost-efficient production.
Yes. The fibre-based carrier layer can be reused or recycled in standard paper recycling systems.
Walki®Soft Foam works seamlessly with Hennecke, Laader Berg, Cannon Viking and other modern slabstock lines.
Walki offers 35 + years of experience, European production reliability, R&D expertise and a strong commitment to circular design.
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