Walki's solutions for the production of soft foam gives optimal reliability and productivity.
You have just driven back from work and you’re relaxing on your favourite sofa. Soft foam is a crucial element in these simple everyday actions. Your car is fitted with it, your sofa is probably padded with it, and it softens the mattress on your bed. It might even be in your shoes.
Chances are that the foam has been made using Walki's soft foam process liner materials as the company is one of the most experienced global suppliers. Customers across Europe, North and South America, and increasingly in Asia and Africa, turn to Walki because of its experience and reliability in the field.
“Productivity, environmental friendliness, and runnability are the most important factors," explains Arno Wolff, Vice president Sales and Marketing Technical Products. “We offer these as well as a long and reliable record of experience in the business, a variety of high value solutions, and the ability to help customers cut costs in their soft foam production process."
Soft foam is produced by injecting polyurethane onto the inner walls of foaming tunnels, each up to 60 metres in length.
The even quality that results from using Walki-PeelFoam to line the walls ensures trouble-free foam production, makes it easier to keep foaming lines clean, runs more easily on a polyurethane line than when using standard polyethylene films and conventional process paper, and keeps the foam free of moisture and dirt when the foam is in stock.
With Walki®Peel Foam, paper is peeled off when the foam block is allowed to set or ‘cure’. The polymer layer is retained, continuing to protect the block from cracking, improving the foam quality, or other damage during storage.
Walki-Foam products respond to the customers' need to eliminate waste of chemicals, which account for as much as 97% of production costs.
“Our solutions can reduce waste in the production process by as much as 3%," says Wolff. The solution eliminates web breaks, chemical leaks that lead to process interruptions. After peeling, the paper can either be recycled or resold, so the customer gets added value in the form of potential extra profit.
“We have been offering the best solution for this production process for the last three decades," says Wolff. “We use the best possible paper from Scandinavia that’s perfectly suited for this product."
Walki-Foam’s production is based at the group’s Valkeakoski and Pietarsaari plants in Finland with additional back up in Germany. “Our pilot machine allows us to develop new products, such as those with flame retardant qualities and polyethylene terephthalate, or PET, film," says Wolff. “The most important aspect for customers is overall cost, but it’s also necessary to meet the safety regulation demands and environmental considerations."