Espoo, Finland -- New paper products from Finnish group Walki will help producers of flexible foam save money and have a cleaner environment.
Walki claims that using WalkiPeel Foam or WalkiCover foam protection materials helps producers of flexible polyurethane foam blocks to cut costly chemical consumption, while at the same time reduce waste in manufacturing.
The Finnish company is a global supplier of carrier material for the foaming industry and says it has spent many years developing its paper-based Walki-Foam products.
The new peelable materials are used to cover all of the inner walls of the foaming line on which the polyurethane is injected and where it expands, giving stable production quality and good chemical hold out, which ultimately leads to cost savings and higher profits.
With chemicals expenses accounting for as much as 97 percent of production costs in polyurethane foam manufacturing, there is no room for wastage in process. Using Walki-Foam products is estimated to reduce raw material costs by some three percent, the company says.
"The high and even quality of our Walki-Foam materials also helps to ensure trouble free foam production, makes it easier to keep foaming lines clean, and runs easily on a PU-line compared with standard polyethylene films and conventional processing paper," said Kari Salminen, business line manager at Walki's Technical Products -division, in the company's announcement.
"Moreover, we offer reasonably short lead times, of two to three weeks, for most of our process liner materials," Salminen added.
Walki's peelable protection material can be used as a top, side, and bottom layer in PU-foaming, while WalkiCover Foam is a universal carrier in the foaming process.
"Both products combine high-quality and recyclable kraft paper with a very thin polymer layer that is specially developed for the foam industry to ease up the foam production process and protect the ready PU block against excessive moisture, dirt, and harmful effects of UV-light,"sais Salminen.
The paper layer is peeled off when the foam block comes off the line for curing, while the PE layer stays in place forming a protective barrier around the final product. This layer also prevents the paper from flex cracking during production, ensuring less machine stops and cleaning procedures and avoiding longer set-up times.
The recyclable material creates less waste, transforming manufacturing waste into profit, the company said.
"Standard polyethylene films used by some manufacturers are very thick adding to the environmental burden. Our paper-based products help to create significantly less waste in manufacturing. The kraft paper can be recycled, or even sold forward for an additional profit," Salminen said.