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2007 Trocellen GmbH

foaminfunction
AS POWERFUL AS THE PEOPLE
An overview of the product lines
A company and its products are as powerful as the people
behind it. With conviction and also with unusual ideas if required.
This is how we work. As developers, producers, problem solvers
and service providers in one. Our most important goal is to find
efficient solutions for the most diverse demands. Which is why we
also conduct intensive product development in cooperation with
our customer. This ensures that our products are perfect. Also
in terms of environmental protection. We have already reached a

INTERNATIONAL AS THE CUSTOMERS


very high standard, because sustainability and the protection of
our environment are firmly anchored in our corporate philosophy.
The environmental aspects are considered in every management
decision, in all functions and on all process levels. For years, we
have been working on avoiding environmental burdens and aim to
reintroduce all raw materials used into the recycling loop in a sensible and energy-efficient manner. For us, this is part of innovative
product development.

The shortest routes to our locations


Headquarters
TROCELLEN GmbH Deutschland
Mlheimer Strae 26
53840 Troisdorf
Germany
Phone: +49 2241 85 04
Fax: +49 2241 85 37 53

TROCELLEN France S.a.r.l.


2, Alle de la Fresnerie
78330 Fontenay le Fleury
France
Phone: +33 130 85 93 40
Fax: +33 130 85 93 44

Polifoam Plastic Polska Sp. z o.o.


ul. Zgierska 40
95070 Aleksandrw Ldzki
Poland
Phone: +48 42 712 12 96
Fax: +48 42 712 12 89

For a better overview, we have divided our very diverse products


into three groups, based on the production method

TROCELLEN Italia S.p.A.


Via dei Dossi 7/9
S.S. 525 del Brembo
24040 Osio Sopra (BG)
Italy
Phone: +39 035 50 70 11
Fax: +39 035 50 21 74

TROCELLEN GmbH UK Office


Central Chambers, 77 Westborough
Scarborough, North Yorkshire
YO11 1 TP
United Kingdom
Phone: +44 1723 376 111
Fax: +44 1723 376 444

TROCELLEN S.E.A. Sdn Bhd


Lot 2213, Kg.Batu 9 Kebun Baru,
Jalan Kasawari,
42500 Telok Panglima Garang
Selangor Darul Ehsan
Malaysia
Phone: +60 3 31 22 12 13
Fax: +60 3 31 22 12 11

TROCELLEN Italia S.p.A.


Sales Office
Via Dante, 3
20040 Caponago (MI)
Italy
Phone: +39 02 959 621
Fax: +39 02 959 62 235

TROCELLEN Rus
141402 Moskovskaja oblast
Himki-2, post box 186
Russian Federation
Phone: +7 495 739 44 38
Fax: +7 495 739 44 21

TROCELLEN Ibrica S.A.


C/Avila, s/n
28804 Alcal de Henares
Spain
Phone: +34 91 885 55 00
Fax: +34 91 885 55 01

Polifoam Plastic Processing Co. Ltd.


Hungary
Tbls u. 32
1097 Budapest
Hungary
Phone: +36 13 47 98 00
Fax: +36 12 80 67 08

CLASSIC

TROCELLEN CLASSIC
TROCELLEN classic, our core product line, consists of horizontally foamed XLPO material manu
factured in rolls or sheets. Since 1972 these foams are regarded as an industry standard based on
their proven application performance. Within this product line we produce two foam variations that
differ in cross-linking technique:
Chemically crosslinked foams (C-foams) are characterized by their very abrasion resistant surface
and excellent thermomouldability, which makes them suitable for very technical applications.
Physically crosslinked foams (P-foams). Due to the physical cross-linking process our p-foams show
very specific properties, differing from c-foams especially in surface and cell structure, but also in
other values like thermal properties, tensile strength, compression set, shrinkage or fogging values.
TROCELLEN classic rolls and sheets are typically offered in densities between 25 kg/m3 and
250kg/m3. The thickness varies between 2 mm and 20 mm. We developed a wide range of foam
modifications which can be characterized by certain specific properties, e.g.: Fire resistance, Temperature resistance, Softness, Hardness (Rigidity).

AS LIVELY AS LIFE ITSELF


What the foam company is all about
Foam accompanies you in many areas of your life. And TROCELLEN makes
sure its there. As Europes leading supplier of cross-linked PO foams. Since
2005 a subsidiary of the Japanese companies Furukawa Electric and Otsuka
Chemical. Together we make our foams successful worldwide.
With more than 600 employees at nine locations, we offer solutions for the
widest range of industries and applications. Our Sport and Shoe, Automotive,
Construction, Insulation, Adhesive Tapes, General Conversion and Packaging
business units make products for all requirements. Flexible and perfectly geared

SHOE

to the needs of our customers. In other words foam in function! As lively as


life itself.
And because this always throws up new aspects, we continuously adapt our range of services to the current challenges. Because we want to offer you the best
results always and inspire you with the latest developments. So were
creative. Full of energy. Every day.
We live foam. TROCELLEN the foam company

World-leading supplier of cross-linked polyolefin foams

VERTICAL

TROCELLEN VERTICAL
These physically cross-linked polyolefin foams offer massive potential for a wide range of applications, where very thin foams with a smooth surface and a fine cell structure are required.
TROCELLEN vertical is produced in thicknesses between 0,5 and 6 mm and in densities varying from
25 to 180 kg/m3.
Crosslinking by irradiation and vertical foaming technology also permits the incorporation of polypropylene (PP) as a base resin for foam production. Foams manufactured from PP show a higher
temperature resistance.

TROCELLEN GmbH
TROCELLEN UK

Polifoam Plastic Processing Co.Ltd.


Polifoam Polska Sp. z o.o.
TROCELLEN Rus

FOOTWEAR BUSINESS UNIT

TROCELLEN France S.a.r.l.


TROCELLEN Ibrica S.A.
TROCELLEN Italia S.p.A.

BLOC

TROCELLEN BLOC
TROCELLEN S.E.A. Sdn Bhd

Our product line TROCELLEN bloc offers chemically cross-linked blockfoams manufactured by
using a discontinuous foaming process. These foams can be produced in higher thicknesses and
show a very smooth cell structure after removing the skin.
TROCELLEN bloc is manufactured in densities of 25, 30, 45 and 100 kg/m3. Low densities are originally produced in 100 mm thickness, while our high density foam is produced in 40 mm thickness.
All products can be splitted to obtain thin layers, starting from 5 mm upwards.

Sales Office

Foam Production

Converting

Furukawa

www.trocellen.com | info@trocellen.com

Otsuka

The Business Unit Shoe has a multi-disciplinary team that is edicated to servicing the technical needs of footwear customers and
exploring innovative concepts. This Business Unit Shoe integrates
all services and expertise to meet the high levels of demand that
the footwear industry requires today.
The Business Unit Shoe has under the same roof: fully trained
staff; equipment for special testing; and facilities to carry out different converting trials, such as, special laminations and Perforating thermomoulding PE foam.
These intensive R&D activities and application developments
allow TROCELLEN in this environment to explore new concepts
and to find optimum and innovative solutions.

Together with their customers, TROCELLEN have been continuously focusing its R&D activities to meet the increasing demand
for more comfortable and light weight solutions, with existing fully
implemented materials in light weight ski boots, motor boots, cycle, trekking and safety shoes, sandals, city shoes and slippers.
The Business Unit Shoe is constantly working with the central laboratory within the Trocellen Group to being new products via new
formulations to meet changing market remands.
TROCELLEN has always considered the importance of maximizing the comfort of foam used in the footwear sector, as well
as providing guidance in designing for light weight in all kinds
of shoes.

Stuffing for collar


- PE + adhesive
- EVA + adhesive
- HLC or reticulated poly urethane foam + adhesive *
- EPDM + adhesive
- Agglomerate foam + adhesive

Internal Lining
- MTP or HLC polyurethane foam
+ fabrics (on one or both sides)
Stuffing for Tongue
- PE + adhesive
- EVA + adhesive
- HLC or reticulated polyurethane
foam + adhesive *
- EPDM + adhesive
- Agglomerate foam + adhesive

* for reticulated foam the adhesive


could be in stripes, too

Lining
Stuffing for Tongue
(the same materials asstuffing)
- Agglomerate foam
+ adhesive PE
- EVA foam + adhesive PE
Reinforcements
- Extruded EVA

* for reticulated foam the adhesive


could be in stripes, too

Insole
- Thermoformed PE +
fabric or leather
- Just simple PE cut
- EVA foam
- Block PE
- Felt

Stuffing
- Agglomerate foam + adhesive PE
- EVA foam + adhesive PE
- Polyethylene foam + adhesive PE
- HLC polyurethane foam +
adhesive PE
- A sandwich of two or more
materials listed above

Upper
- Perforated or not perforated PE foam
+ synthetic fabric (PES; PA, PP, EL VI, CO)

Lining
- PE foam+ MTP polyurethane
foam + fabrics
- HLC polyurethane foam +
fabrics + MTP polyurethane
foam + fabrics
- MTP polyurethane foam +
fabrics

Stuffing
- Agglomerate foam + adhesive PE
- EVA foam + adhesive PE
- Polyethylene foam + adhesive PE
- HLC polyurethane foam + adhesive PE
- A sandwich of two or more materials
listed above

Reinforcements
- Extruded EVA

Upper
- PE + different types of textiles
- PE + aluminium film + textiles

Insole
- Thermoformed PE
- Felt
- Block PE

Tip Stuffing
- EPDM + textiles

MOTOR BOOTS

CYCLE SHOES

SAFETY SHOES

TREKKING SHOES

SKI BOOTS

STREET SHOES

SANDALS

SLIPPERS

These types of sport shoes require comfortable and at the same


time resilient materials. For this reason R & D men find it
useful to combine our TROCELLEN PE foams with polyurethane foams and/or elastic materials like EPDM foam used for stuffing.

Breathable lining and comfortable insoles are a must for cycle


shoes. These characteristics can be satisfied by new particular
textiles laminated to polyurethane foams and insoles produced
with innovative foams like: TROCELLEN comfort.03 &/or D03
foams laminated to absorbent textiles and perforated under the
toe-end.
.

Protection against steel (or other material) safety heel and antistatic/conductive insoles are the applications for TROCELLEN
converted products. Conductive PE -and Polyurethane foams
with adhesive in strips are products created on purpose for safety shoes.

As the drawing above shows, TROCELLEN can be used with


adhesive for stuffing, perforation and lamination to Nylon for
Upper and combined with different types of textiles, anti-shock
gel or EVA for insoles.

There are two different constructions of internal ski boots: the


traditional one (see above drawing) where different types of materials, PE, EPDM, Extruded EVA, agglomerate and polyurethane
foams are sewn together and the thermoformed one in which the
entire boot is produced using PE foam laminated to textile and
then thermoformed.

Expanded foam products from TROCELLEN are used in very


diverse forms in shoe construction, for example as cuff cushioning, inner lining, upper materials (with very finely perforated
PE foam) and eyelet reinforcements.

TROCELLEN polyethylene foams can be used to fill sandals


soles in order to lighten them. PE Foams with EVA additives can
be found in applications in production of insoles for injected
sandals. EPDM foam laminated to elastic textiles is a valid solution for upper.

Main application of TROCELLEN products in this type of shoes


is for insoles, lining and uppers.

SOLE INLAYS
Consist of various types of PE foam heat-laminated or sewn with
numerous textiles, active carbon materials, leather etc. and then
thermally moulded or stamped flat.