ALEA / SHAPE AND SUBSTANCE

Expertise and services

Development and optimisation of polyurethane systems

Development of new formulations and optimisation of existing ones, including the selection of raw materials and auxiliaries.
Chemical and mechanical testing: remote support, assistance at your laboratories or testing carried out directly in laboratories available to us.
Support in organising the chemical laboratory, from instrument selection to establishing test methods and quality control procedures.
Support in selecting mixing plants and reactors and setting up system production: operating procedures, logistics and quality control.
Support during production start-up, including assessment of results and fine-tuning of operating conditions.

Start-up and optimisation of polyurethane product manufacturing

Organisation of production areas and positioning of plant and equipment to suit workflow and material flow.
Support in selecting and installing production plants, foaming machines, moulds and auxiliary equipment to suit the product and production requirements.
Selection of raw materials, polyurethane systems and chemical auxiliaries, such as release agents, colourants, coatings and additives, to suit the application.
Production process setup and optimisation, including work methods and timings, operating procedures, quality control and logistics planning.

REQUIREMENTS AND REFERENCES

Fire performance

Development and fine-tuning of polyurethane systems to meet the fire performance requirements for the application.

For example, depending on the application:

BS 5852 — Crib 5
Italian class 1 IM under UNI 9175
California TB 117-2013
FMVSS 302
ISO 3795
EN 45545-2

Emissions and restricted substances

Development and fine-tuning of polyurethane systems to meet specific requirements for emissions and restricted substance content.

Including requirements set by:

Blauer Engel
LGA-tested for contaminants
CertiPUR
OEKO-TEX STANDARD 100
IKEA technical specifications

POLYURETHANE SYSTEMS

Different systems.
The same focus on your project.

Flexible and viscoelastic foams +

Systems for high-resilience (HR) and viscoelastic foams (memory foam), for moulding and for discontinuous block production. Applications include cushions, mattresses, seating and padding.

High-resilience flexible foams (HR)

MDI- and TDI-based moulding systems;
Systems for discontinuous block production.

Viscoelastic foams (memory foam)

Systems for moulded pillows and mattresses;
Systems for discontinuous block production;
Pneumatic and chemical viscoelastic systems.

Integral skin and microcellular systems +

Integral skin systems and polyether (PET) and polyester (PES) microcellular systems for applications such as armrests, grips, soles, midsoles and Fussbett footbeds.

Flexible integral skin systems

Experience with systems blown with HFC-134a, HFC-365mfc/HFC-227ea blends and HFC-245fa, for applications and markets where their use is permitted;
Systems blown with HCFO-1233zd(E) and HFO-1336mzz(Z);
Water-blown systems;
Viscoelastic integral skin systems, blown with water and/or physical blowing agents.

Footwear

Polyether (PET) and polyester (PES) systems;
Systems for injection and casting;
Single- and dual-density soles, outsoles and midsoles;
Systems for safety footwear;
Systems for Fussbett footbeds, insoles, slippers and boots.

Elastomers, gels and prepolymers +

Cold-cast elastomer systems, polyurethane gels and prepolymers. Applications include wheels, rollers, seals and cushioning components.

Structural rigid systems +

Solid and foamed structural rigid polyurethane systems for applications such as shells, housings and furniture components.

SECTORS AND APPLICATIONS

Applications

We support customers in the development, optimisation, prototyping and industrialisation of polyurethane products, through to production process setup, for applications across different sectors.

Examples of sectors and applications include:

Furniture: sofas, armchairs, seating, armrests and cushions;
Automotive: steering wheels, seats, armrests, headrests, headliners, dashboards and air filters;
Bedding: pillows and mattresses made from viscoelastic foams, HR foams and gels;
Footwear: soles, midsoles, outsoles, insoles, safety footwear, boots and slippers;
Medical: pressure-relieving seating and protective padding;
Technical products: bumpers, seals, wheels, cable protectors, abrasive discs and small wheels;
Bathroom fittings: headrests and shower trays;
Playgrounds: seats, protective padding and swings;
Agglomerates for various applications: rubber, foam and cork.

THE NEXT STEP

What is your
next direction?

Let’s talk ↗

info@aleapur.com