Polyurethane packaging: effective solutions for protection and transportation

Polyurethane packaging: logistical challenges

Once produced, flexible polyurethane foam is sent to the industries responsible for its conversion. At this stage, the material is mainly in the form of blocks, slabs or rolls, which are characterised by considerable weight and bulk. While these configurations are efficient for large-scale production, they present significant logistical challenges in terms of handling and transportation.

Once the polyurethane blocks and rolls arrive at specialised plants for further processing, they are subjected to high-precision cutting and shaping processes.  The end result is panels of different sizes or elements with specific shapes for different applications. These products, often intended for the assembly of items such as mattresses, sofas and components for the automotive and other industries, require versatile packaging machines capable of adapting to the heterogeneity of shapes and sizes.
 

Optimal packaging requirements for polyurethane blocks and rolls

Optimal packaging for flexible polyurethane not only protects the material, but also actively contributes to logistics efficiency by reducing costs, optimising space and speeding up operations. 
 

To achieve this, the packaging must meet certain basic requirements:
 

Protection:

• Mechanical resistance: the packaging must be strong enough to allow handling of the product during transport and storage. 
• Insulation: for certain types of polyurethane, the packaging must protect them from moisture and oxygen, which can affect their physical and chemical properties.
• Stability: the packaging must prevent the sheets from moving or deforming during transport, avoiding damage and preserving the aesthetic appearance of the product. 
   

Efficiency:

• The packaging must minimise the volume taken up by the flexible polyurethane foam, whether in blocks, slabs or sheets, to optimise transport and storage costs.
• Lightness: the weight of the packaging must be limited so as not to affect transport costs.
   

Practicality:

• Ease of handling: packaging must be designed to be easy to handle, facilitating efficient transport, loading and unloading of materials. This not only reduces handling time, but also improves the overall efficiency of the supply chain.
• Reduced packing time: well-designed packaging should allow for quick packing, optimising production time and enabling more agile and faster handling.
• Optimised storage: its shape must facilitate storage and minimise the space taken up in the warehouse.
   

Packaging that meets all these requirements not only helps to reduce overall costs, but also improves operational efficiency by ensuring that the flexible polyurethane foam arrives at its destination in the best possible condition, ready for further processing.
 

Polyurethane packaging machines: Dolphin Pack solutions

It is precisely to meet these needs that Dolphin Pack has designed and developed a complete range of polyurethane packaging machines, including a patented machine capable of handling the different shapes and sizes that this versatile material can take, satisfying every analysed requirement.
 

Whether large rolls of polyurethane or sheets and shapes, our machines offer state of the art packaging solutions. Our fully automatic and fast systems enable
 

• Compress bulky products flat or in rolls, significantly reducing their bulk and optimising transport costs. This also reduces the risk of damage during handling, as the products take up less space and are easier to handle. Dolphin Pack has developed three machines specifically for this type of compression:
  
  • The Levante polyurethane packer, a compact and efficient compression system that combines strength and high-precision mechanics to reduce the volume of blocks and rolls by up to 80 per cent and cut transport costs.
  • The patented Pelèr polyurethane packaging machine, the ideal machine for vacuum packaging and vacuum compressing polyurethane blocks and slabs, allowing the volume of the product to be reduced by up to 80%. 
  • The Burian polyurethane packaging machine, Dolphin Pack's new entry into the market, combines the advantages of the Levante and Pelèr lines. This innovative system combines the flat packaging typical of the Levante with the exceptional compactness guaranteed by the roll-up characteristic of the Pelèr. Thanks to the integration of Ander Roll R BL technology, Burian can reduce product volume by up to 80%, offering a complete solution that maximises packaging efficiency and halves packaging costs.
     
• Pack several polyurethane panels and slabs together to create a stronger, more compact load unit. This further optimises transport costs and simplifies warehouse management. Our machines are capable of safely and accurately wrapping multiple products, ensuring maximum protection at all stages of the supply chain. It is for this type of wrapping that Dolphin Pack has developed the Mistral 3B MCL, an ideal machine for polyurethane foam and rigid polyurethane producers who need to wrap multiple moulded products with a high quality result. With its compact design and automatic size detection system, the Mistral 3B MCL is perfect for speeding up production and can be easily integrated into any line.

• Speed up your packaging process. Thanks to automated processes and state-of-the-art technology, Dolphin Pack's packaging machines guarantee fast and efficient packaging. This results in higher productivity, shorter cycle times and reduced resource consumption.  In addition, the speed of packaging helps to reduce waiting times and avoid bottlenecks in the production line.

• Protect against moisture and oxidation. Thanks to the use of plastic films that act as a protective barrier, the packaging provides an effective defence against external agents.

• Reduce the use of plastic film, thanks to technologies that optimise the sealing and cutting process of the film, minimising waste, and thanks to the compression of products, which allows less packaging material to be used.  This approach not only reduces material costs but also helps to minimise the environmental impact of packaging.
   

Choosing Dolphin Pack means choosing an experienced and innovative partner, able to offer polyurethane packaging solutions tailored to the specific needs of each company.

Would you like to know more about Dolphin Pack's polyurethane packaging solutions? Contact Dolphin Pack for a personalised consultation and discover the best solution for your needs!

From 12 to 14 November, we will also be present at the Polyurethane Foam Association (PFA) conference in New Orleans, where we will be talking about polyurethane packaging and compression to optimise logistics and transport!