Items
that Use Foam
- automobile seats
- cushions
- lounge chairs
- children toys
- mattresses
- pillows
- footwear
- pads
How to Setup Foam
Production Company
Foams generally come in different shapes and sizes. You
have the soft or hard foam based on the chemical and manufacturing process.
To start a production line you need equipment, raw
materials funding. Before setting up the business carry out a market survey
then learn the trade. The next step is to focus on a niche like mattresses,
pillows, cushions or automobile seats.
Purchase
Equipment
Purchase equipment and hire experienced staff to operate
the machinery. You need funding for both fixed and working capital.
Approach a local bank for short or long term loans. You
must show proof of profitability, business plan and proof of incorporation.
Register
the Business
Register the business as a LLC then find an ideal factory
location. You can apply branding or patent your logo. To remain competitive put
your products to regular quality tests.
Raw Materials
The company should have a ready source of raw materials.
The major chemicals in foam are liquid polymers, water.
The polyisocyntes are found in petrochemicals. TDI are ideal
for the manufacture of flexible foam while MDI are use for rigid foams. Blowing
agents are used to form bubbles, surfcants to control the bubble sizes.
The Manufacturing
Process
Liquid chemicals are placed into holding tanks separately.
They are then pumped into heated mix tanks.
Continuous dispensation is used to produce rigid foam
before cutting or curing. To achieve flexible foam dispensing machines vary the
chemical output.
It is impotent the final product undergoes quality
control tests. Quality control test include spring tension, weight, thickness, load
bearing. The byproduct is recyclable into bonded carpet cushion.
How Foam
is made
Foam is made either with batch process, slab stock or continuous
process. It is formed when gas bubbles is introduced into a plastic mixture.
It can be molded or cut into different shapes or sizes.
The two types of foam are the rigid foam or flexible foam.
The rigid foams feature a tough polymer cell that
prevents gas movement. The flexible foams have open structure and are perfect insulators
for building or refrigerators. The flexible foams are common in automobiles, footwear,
pillows and mattresses.
Marketing
Marketing is challenging because there are many players
in the industry. You need to brand your product and use different advertisement
methods.
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