"Smart Factory" for Technical Foam Solutions

New FoamPartner Converting Center GmbH complements FoamPartner Group's existing expertise by providing a vertically integrated value chain from foam production to customized precision components. Just 12 months after groundbreaking in April 2019, FoamPartner commissioned its state-of-the-art foam converting center at the company's Duderstadt facility in Germany. By the end of June 2020, the new plant had produced more than 1,000 different parts and components. When the new facility becomes fully operational this October, this figure is expected to exceed 5,000. The 8,500-square-meter center represents an investment of EUR 10 million, has created 50 new jobs, and is expected to obtain ISO 9001 certification by year end. Vice President of the European Business Division Tobias Gruener said "Since the project began in September 2018, our project team has worked hard to complete this center in the shortest possible time. Despite the difficult conditions caused by COVID-19, production commenced in April 2020," and added "The center is designed as a 'Smart Factory' according to Industry 4.0 principles, featuring a highly digitalized and automated workflow."

Flexible Production with More Than 50 Different Machines

Key features of the new FoamPartner Converting Center include a thermal press for controlled millimeter-step compression of foam layers, particularly important for filtration foams. The center's modular design with more than 50 machines, some specially designed to FoamPartner's specific requirements, enables a highly efficient and flexible combination of diverse processing and production technologies. The capacity range includes horizontal separation and vertical cutting of foam sheets, die cutting and various stamping operations, horizontal and multi-spindle drilling, milling, thermal compression, welding, adhesive bonding, lamination and impregnation processes. A small-scale processing center for low-volume specialty products is also available. SAP S/4 Hana ERP software ensures efficient planning, transparent coordination and traceability of all business processes from procurement through manufacturing to shipping. A real-time logistics system (RTLS) with scanners and industrial computers at all production workstations provides paperless material flow. Semi-autonomous material handling is accomplished by automated guided vehicles (AGVs) and floor-mounted conveyors in the storage area, utilizing facility-wide WLAN. Finished products are extracted by fully autonomous robots. Robot systems are also deployed for cleaning operations.

Enhanced Competitiveness, Safety and Sustainability

FoamPartner CEO Dr. Michael Riedel stated "The new Converting Center sets new standards in the production of foam product solutions. Aerodynamic material management, industrial-scale operations and consistent digitalization enhance our capabilities for precision products in larger volumes without compromising flexibility for smaller orders. By bringing together our expertise—R&D, foam production, processing, application engineering, prototyping, etc.—we now deliver the entire value chain to our customers with the fastest possible lead times and highest quality and competitiveness on the market." This new, greenfield investment center also meets requirements for energy and material efficiency that minimize waste and increase production sustainability, as well as resource-saving work order planning. Additionally, the work environment is designed to state-of-the-art ergonomic standards to ensure maximum occupational safety and health protection.

Leading Company in Technical PUR Foams

The FoamPartner Converting Center in Duderstadt, like the neighboring operations of FoamPartner Germany GmbH, sources the majority of technical foam from three group-owned foam production facilities in Europe. This reduces transportation requirements and optimizes carbon footprint. A global player in the polyurethane ester and ether foam market, FoamPartner specializes in a wide range of demanding application markets, including:

• Acoustic foams for sound insulation in white goods such as vacuum cleaners and washing machines. Acoustic foams for sound insulation of industrial equipment such as generators, and also for building, construction and room acoustics applications.
• Sealing foams for reliable sealing against liquids, gases and air, dust and dirt, sound, vibration and heat. These foams are required in building and construction, e.g. for ventilation systems or combination boilers, as well as in device engineering, e.g. for vending machines.
• Filtration foams for use in air and activated carbon filters in air conditioning systems, water filters in aquariums, and storage filters in printing presses.
• Microphone windscreens and headphone ear cushions in broadcasting, television and studio engineering.
• Packaging solutions made from foam for the protection, display and transport of precision and valuable goods.