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Polyurethane foam scrap as a by-product in the automotive sector

PROSEAT FOAM MANUFACTURING, SLU is a company that manufactures non-electric parts and accessories for motor vehicles. The company manufactures polyurethane models from the reaction of raw materials: isocyanates, polyols, catalysts and additives. The chemical components are injected into the hot aluminium molds (closed hot water circuits) and when the mold is closed, the components react with each other forming the polyurethane foam.

In the process of demolding the pieces, all those that have not been in accordance with the corresponding quality criteria are considered defective parts, called scrap (pieces of rejection).

These rejected pieces are managed as a by-product in the Catalan regulatory framework and are used in the process of the CATENSA SANO INDUSTRIAL GROUP, which is dedicated to the manufacture of textile products for technical and industrial use, specifically thermoformed pieces to soundproof the interior of automobiles. In these facilities, the residue of polyurethane foam is subjected to mechanical trituration with grinders together with textile lint, with which it is mixed to obtain the pieces that are molded by heat and pressure. These parts are installed inside the different types of vehicles for their soundproofing.

The use of the polyurethane foam as a by-product is a great benefit for both companies, on the one hand there is an economic saving related to the waste management and on the other hand, the receiving company manages to optimize the cost of the raw materials used, becoming more competitive in the market.