Write up on flexible slabstock Polyurethane Foam

Manufacturing a polyurethane foam is similar to making a cake. You have a batter and then you bake
it (causing it to expand) and you get a fluffy cake. Similarly, you have a chemical mix which when
exposed to a blowing agent and a catalyst causes the mix to expand and cool down to become a
foam.

Video- https://youtu.be/zi7am1We9SE

Following are the chemicals used for manufacturing slabstock

1. Polyether Polyol 3000 MW (We supply Covestro Polyol)

2. TDI - Toluene diisocyanate (We supply Covestro TDI or GNFC make)
3. Water blowing agent . Sometime some also use Methylene chloride as co-blowing agent
4. Silicone Surfactant
5. Stannous Octoate / T-9 catalyst
6. Amine catalyst
7. Fire retardant - TCPP (if fire resistant foam is the requirement)
8. PU pigment paste (Tandy make)
9. Fillers are sometimes used like Calcium carbonate

This is a typical manufacturing process in continuous plant. Similar process is followed except that
the chemicals are mixed together and poured into the mould. Then the foam is allowed to cure.
Kindly see the above video link.

Every manufacturer have their own recipe to make the bunstock/slabstock. Following we found in
literature (whose link we are sharing at the end of the document) on internet that may be useful to
have an idea.
HS 100 - May be optional or manufacturers may be substituting it with other polyol when required.
Surfactant is also added which has not been mentioned here by manufacturer as foam manufacturer
have proprietary recipes.

Reference link -
http://environmentclearance.nic.in/writereaddata/Online/TOR/07_May_2019_180132423NR9I4GL
UAnnexure-PFR.pdf