SPA Polyurethane Foam

Batch numbers of the incoming raw materials are checked and recorded.

All delivered raw materials come with certificate of analysis (CoA) report.

CoA are stored and kept for reference.

Delivered materials come with expiration dates.

Expiration dates of raw materials are recorded and constantly monitored.

Temperature of the delivered materials are inspected and recorded.

Supplier is keeping retains of delivered raw materials (min. 6 months).

Foam producer is verifying the properties of the raw materials according to the requirements of the TDS or CoA.

Materials are stored according to the requirements indicated in the technical data sheet or MSDS (within the maximum and minimum temperature, within the expiration date requirements, free from contamination, etc.).

First in-first out rule (FIFO) is being practiced.

No leakage in the storage tanks and pipes connecting to the storage (pay particular attention to isocyanates storage tanks).

Each foam type produced has its own process scheme (instructions on how to produce including recommended process parameters and troubleshooting schemes).

Isocyanate index within the recommended range (100-120 for STD and HR).

Safety protocols in place for isocyanate index <100 like visco and low density/hardness (fire safety, foam separation, extinguishers, etc).

Water level of all recipes not more rhan 4.8 php

Amount of additives used in the foaming are regularly monitored/recorded (manual or automatic recording is acceptable).

Speed of foaming line is regularly recorded.

Metering pump output of all the raw materials are constantly recorded.

Temperature of polyol and isocyantes are within the recommended workable range.

Curing time for all standard foams are at least 12 hours (check records).

Curing time of all HR foams are at least 12 hours (check records).

Curing time of VE foams and other specialty foams are at least 24 hours (check records).

Temperature of the foam cores are monitored per batch and kept under control for max 165 C.

Conditioning time for all standard grade foams is at least 48 hours (check records).

Conditioning time for other foam types (HR, visco, plush, etc.) is at least 72 hours (check records).

Conditioning time for pre-pressed/compressed foams is at least 72 hours (check records).

Foam producer has a built-in foam crushing procedure (includes compression rate different foam types).

Foam producer verifies the physical-mechanical properties of the foam according to IoS Mat 0076 requirements (each batch, average from top, middle and bottom samples of the foam block).

All foam tests and results are logged and can be readily available to IKEA upon request.

Equipment and tools used in the verification of foam quality are regularly calibrated (check calibration records or stickers in the instruments).

Foams are stored and kept in such a manner wherein they are isolated from other potential sources of VOC and odor (smoke from emissions of forklift, machines, etc.)

Foams are stored in an area where it is not directly exposed to sunlight, heat and water.