A step by step process.
Before manufacture begins, the most important process happens – we select what composition of polyurethane foam structure the underlay is to be made from. Most PU Underlays on the market are made from shredding on many kinds of foams across many spectrums of the market such as clothing foams, automotive foams, sofa & furniture foams etc. This is the cheapest option available which is why many PU Foams on the market look multi-coloured in their construction. However, Wilsons focuses on using virgin memory foam which is a much more expensive material but performs far greater than standard PU Foams. To understand more on memory foam, check out our Plushwalk® page here.
Wilsons Underlays over the years have found ways to speed up the process through combining certain processes together thus resulting in improved production times and a lower CO2 footprint.
Once the selection of foams is complete, the foams must be shredded in order to be re-structured into an underlay. The first process the foams go through shredding machines and then finally through a specialised grinder which puts the foam back into its smallest form. Once the foams have been shredded into their smallest form, they are then inserted into a cylinder drum which is then subjected to pressure & heat to reconnect all the foams together. This process takes several hours to complete and then after completion, the block of foam goes through a curing process which the foam is allowed to cool and revitalise.
Once the block of foam is cured, the block of foam goes onto a peeling machine where it is cut to the desired thickness required. It is a rotation device that moves the foam clockwise whilst a moving cutter blade accurately cuts the foam to usually 8mm, 9mm, 10mm, 11mm or 12mm thickness.
In the final process, the peeled foam then goes through a laminating machine where the backings are fused to the foam through a heated process. Wilsons Underlays have developed a bespoke machine which enables a cleaner & more efficient way of installing backings through a pressure method. The backings chosen can be almost unlimited in choice, but in the underlay world, these are either a stitched-paper backing or a PE printed material which for example Plushwalk uses – 1 side has a damp proof membrane and the other has a smooth fit backing which helps aid installation.
Once the underlay has undergone the backing process, it is automatically cut into the appropriate roll lengths.
The rolls of underlay are now almost ready! After undergoing quality assurance checking, each roll is automatically bagged. To ensure we have as little environmental impact as possible, we now heat seal our bags rather than using additional plastic ties.
Order a free sample booklet today.
We’re so confident in our underlays that we are offering free samples to anyone who requests them. You can request up to three sample booklets delivered to your door free of charge for any of our underlays, which each have their own sample booklet. If you’re looking for a domestic underlay, we highly recommend taking a look at Plushwalk 12mm.
