Dow-Recticel Innovation Drive Secures MDI-Foam Sales Success in Sport

Dow-Recticel Innovation Drive Secures MDI-Foam Sales Success in Sport
Technical Teamwork Supports Further Market Expansion

Midland, MI - May 12, 2009

Hundreds of the world’s leading sporting arenas have come to rely on an innovative MDI-based composite foam for playing surface underlays developed by polyurethane foam specialist Recticel – with technical support from The Dow Chemical Company (Dow).

Headquartered in Brussels, Belgium, but with global reach, Recticel produces semi-finished foam products as well as finished goods for the flexible foams, bedding, insulation and automotive industries. The company has developed an enviable reputation in the provision of high-quality underlays for indoor and outdoor sports floors under its re-bounce^® brand name, and in 2008 sold over three million m² of such products to 28 countries worldwide.

The company has also seen a 32% annual growth rate for the re-bounce^® product range in the last three consecutive years, an impressive sales hike which is testament to the strength of a long term technical collaboration between Recticel and Dow – a team effort which is now leading to similar successes in other applications.

Recticel approached Dow to help complete phase out of its self-formulated TDI-based binders for composite foam applications in the early 2000s, due to increasing safety standards required at its production facilities. Dow’s challenge was to develop a binder which would deliver the right pre-polymer cross linking density and softness – a characteristic associated with TDI-based pre-polymers – and still deliver the mechanical properties required.

“It was vital that we had a product that would not compromise the mechanical properties required for re-bounce foam, which had proved successful for indoor sport applications when we launched it in 1998 and which saw further success when we expanded to outdoor arenas in 2001,” said Bart ten Brink, Group Business Unit Manager at Recticel. “Time was also of the essence, because our customers were perfectly happy with the foams produced with our previous TDI-based pre-polymer and we wanted to ensure a seamless transition for them.”

The joint work resulted in the qualification of MDI pre-polymer grade VORAMER^TM RF 1025 Isocyanate at a number of Recticel’s composite foam manufacturing sites, supporting the company’s TDI-reduction plans in composite foams. The binder is now used across Recticel’s expanding range of re-bounce underlay products for indoor and outdoor sports surfaces.

Indoor floors laid with Recticel’s re-bounce underlay provide ideal characteristics for running or jumping, with sports floor manufacturers having a choice of products with a range of density, hardness and thickness variations that provide exactly the specific properties for rubber, linoleum, PU, wood or PVC surfaces.

The re-bounce range also includes high quality mats for combat sports as well as gymnastics, whilst tailored product “re-bounce^® football” gives the same level of performance as top quality natural grass when used in combination with artificial turf. Recticel has also created “re-bounce^® outdoor”, a weather durable underlay product with an excellent long-term performance for shock absorption, ball bounce and water permeability.

The sporting success prompted further trials with MDI-based pre-polymers in another Recticel application – thermoformed foam for shoe soles - a project which resulted in the development of an entirely new Dow product and another increase in sales for Recticel.

“We were pleased with the performance of Dow’s VORAMER^TM RF 1025 Isocyanate in foam underlay applications and wanted to investigate whether it could lead to further reductions in TDI-based pre-polymers in another of our key markets, shoe applications,” explained Bart ten Brink. “However, we required excellent thermo-forming capabilities and exceptional softness for such an application, which mean further research and development was needed.”

The businesses began work on an entirely new MDI-based pre-polymer this time designed specifically for thermoforming, with trials demonstrating yet further improvements compared to the original solution, particularly in tear strength.

Composite foam produced with the new binder – commercialized as VORAMER^TM MF 1504 Isocyanate – produced excellent performance in trials against Recticel’s previously-used TDI composite foam, and made the journey from initial sample to bulk order in just six months.

“The new requirement was to replace a TDI-based grade that Recticel had been using for shoe sole applications, and we achieved that by controlling the pre-polymer functionality and the use of a acceptable diluents from an environment, health and safety perspective,” said Andrew Miller, Systems House Director at The Dow Chemical Company. “This enabled us to meet the requirements of high mechanical performance, excellent thermo-formability, ease of processing and, perhaps most importantly, environment, health and safety improvements at the same time.”

“Both projects provide great examples of how two companies working closely together to solve specific challenges can not only achieve the results originally desired, but can actually exceed expectations by sharing ideas,” added Bart ten Brink of Recticel. “It’s a perfect reminder that even in these tough times industry hasn’t lost its power to innovate, and that by developing solutions designed to push a market forward we can continue to create opportunities for growth.

“In particular, the development of new, safer products for production of sports surfaces has enabled us to further support world-leading suppliers of flooring systems in the sector, and given us the ability to provide tailor-made solutions across the board – this will reinforce our aim of becoming a globally-recognized player which continuously innovates and offers one-stop-shop solutions to its customers.”

Other projects in Recticel and Dow’s pipeline include innovative developments in surfacing for playgrounds, and a new generation of spray coating for foam mats, which is scratch-resistant.

About Dow

About Dow Flooring

As a leading global provider of technologies for soft surfaces and artificial turf, Dow Flooring supplies customers around the world with integrated access to a diverse range of high-quality raw materials. Our polyurethane, latex and elastomer technologies are designed to improve the performance of carpet backing systems with enhanced attributes like flexibility, strength, durability and moisture barrier. For artificial turf, our infill, backing and shock absorption materials offer benefits such as durability, stability and ease of installation. All our technologies are developed with customers’ environmental initiatives in mind including renewable content, recyclability, renewable energy use and extended lifecycle costs.

About Recticel

Under the motto A passion for comfort, Recticel, as a manufacturer of polyurethane foam products, strives to make a real difference to daily comfort for all.

The Group concentrates on four selected fields of application: Flexible foams, Bedding, Insulation and Automotive. Although the Group mainly produces semi-finished products (Flexible foams and Automotive), in a number of divisions it also manufactures finished goods, both consumables and durables (Bedding and Insulation). Within the Bedding division, mattresses and slat bases are sold mainly under well-known brand names (including Beka, Epeda, Lattoflex, Literie Bultex, Schlaraffia, Sembella, Superba, Swissflex, etc.). The Insulation division supplies high-quality finished thermal insulation products, which can be used directly in building projects.

As market leader in most of its activities, Recticel currently provides work for a total of 11,590 employees in 130 establishments in 27 countries. The Group operates predominantly throughout Europe, but it also pursues a number of activities in the United States and Asia. Recticel aims to achieve sustainable, balanced added value and steady, profitable growth for the benefit of its customers and its shareholders.

For Editorial Information:

Jennifer Holzinger
The Dow Chemical Company
+1 989 636 8537

Piet Tytgat
Recticel N.V
+32 9 368 95 87
Tytgat.piet@recticel.com

®™^* Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow

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Headquartered in Brussels, Belgium, but with global reach, Recticel produces semi-finished foam products as well as finished goods for the flexible foams, bedding, insulation and automotive industries. The company has developed an enviable reputation in the provision of high-quality underlays for indoor and outdoor sports floors under its re-bounce^® brand name, and in 2008 sold over three million m² of such products to 28 countries worldwide. The company has also seen a 32% annual growth rate for the re-bounce^® product range in the last three consecutive years, an impressive sales hike which is testament to the strength of a long term technical collaboration between Recticel and Dow – a team effort which is now leading to similar successes in other applications. Recticel approached Dow to help complete phase out of its self-formulated TDI-based binders for composite foam applications in the early 2000s, due to increasing safety standards required at its production facilities. Dow’s challenge was to develop a binder which would deliver the right pre-polymer cross linking density and softness – a characteristic associated with TDI-based pre-polymers – and still deliver the mechanical properties required. “It was vital that we had a product that would not compromise the mechanical properties required for re-bounce foam, which had proved successful for indoor sport applications when we launched it in 1998 and which saw further success when we expanded to outdoor arenas in 2001,” said Bart ten Brink, Group Business Unit Manager at Recticel. “Time was also of the essence, because our customers were perfectly happy with the foams produced with our previous TDI-based pre-polymer and we wanted to ensure a seamless transition for them.” The joint work resulted in the qualification of MDI pre-polymer grade VORAMER^TM RF 1025 Isocyanate at a number of Recticel’s composite foam manufacturing sites, supporting the company’s TDI-reduction plans in composite foams. The binder is now used across Recticel’s expanding range of re-bounce underlay products for indoor and outdoor sports surfaces. Indoor floors laid with Recticel’s re-bounce underlay provide ideal characteristics for running or jumping, with sports floor manufacturers having a choice of products with a range of density, hardness and thickness variations that provide exactly the specific properties for rubber, linoleum, PU, wood or PVC surfaces. The re-bounce range also includes high quality mats for combat sports as well as gymnastics, whilst tailored product “re-bounce^® football” gives the same level of performance as top quality natural grass when used in combination with artificial turf. Recticel has also created “re-bounce^® outdoor”, a weather durable underlay product with an excellent long-term performance for shock absorption, ball bounce and water permeability. The sporting success prompted further trials with MDI-based pre-polymers in another Recticel application – thermoformed foam for shoe soles - a project which resulted in the development of an entirely new Dow product and another increase in sales for Recticel. “We were pleased with the performance of Dow’s VORAMER^TM RF 1025 Isocyanate in foam underlay applications and wanted to investigate whether it could lead to further reductions in TDI-based pre-polymers in another of our key markets, shoe applications,” explained Bart ten Brink. “However, we required excellent thermo-forming capabilities and exceptional softness for such an application, which mean further research and development was needed.” The businesses began work on an entirely new MDI-based pre-polymer this time designed specifically for thermoforming, with trials demonstrating yet further improvements compared to the original solution, particularly in tear strength. Composite foam produced with the new binder – commercialized as VORAMER^TM MF 1504 Isocyanate – produced excellent performance in trials against Recticel’s previously-used TDI composite foam, and made the journey from initial sample to bulk order in just six months. “The new requirement was to replace a TDI-based grade that Recticel had been using for shoe sole applications, and we achieved that by controlling the pre-polymer functionality and the use of a acceptable diluents from an environment, health and safety perspective,” said Andrew Miller, Systems House Director at The Dow Chemical Company. “This enabled us to meet the requirements of high mechanical performance, excellent thermo-formability, ease of processing and, perhaps most importantly, environment, health and safety improvements at the same time.” “Both projects provide great examples of how two companies working closely together to solve specific challenges can not only achieve the results originally desired, but can actually exceed expectations by sharing ideas,” added Bart ten Brink of Recticel. “It’s a perfect reminder that even in these tough times industry hasn’t lost its power to innovate, and that by developing solutions designed to push a market forward we can continue to create opportunities for growth. “In particular, the development of new, safer products for production of sports surfaces has enabled us to further support world-leading suppliers of flooring systems in the sector, and given us the ability to provide tailor-made solutions across the board – this will reinforce our aim of becoming a globally-recognized player which continuously innovates and offers one-stop-shop solutions to its customers.” Other projects in Recticel and Dow’s pipeline include innovative developments in surfacing for playgrounds, and a new generation of spray coating for foam mats, which is scratch-resistant. About Dow About Dow Flooring As a leading global provider of technologies for soft surfaces and artificial turf, Dow Flooring supplies customers around the world with integrated access to a diverse range of high-quality raw materials. Our polyurethane, latex and elastomer technologies are designed to improve the performance of carpet backing systems with enhanced attributes like flexibility, strength, durability and moisture barrier. For artificial turf, our infill, backing and shock absorption materials offer benefits such as durability, stability and ease of installation. All our technologies are developed with customers’ environmental initiatives in mind including renewable content, recyclability, renewable energy use and extended lifecycle costs. About Recticel Under the motto A passion for comfort, Recticel, as a manufacturer of polyurethane foam products, strives to make a real difference to daily comfort for all. The Group concentrates on four selected fields of application: Flexible foams, Bedding, Insulation and Automotive. Although the Group mainly produces semi-finished products (Flexible foams and Automotive), in a number of divisions it also manufactures finished goods, both consumables and durables (Bedding and Insulation). Within the Bedding division, mattresses and slat bases are sold mainly under well-known brand names (including Beka, Epeda, Lattoflex, Literie Bultex, Schlaraffia, Sembella, Superba, Swissflex, etc.). The Insulation division supplies high-quality finished thermal insulation products, which can be used directly in building projects. As market leader in most of its activities, Recticel currently provides work for a total of 11,590 employees in 130 establishments in 27 countries. The Group operates predominantly throughout Europe, but it also pursues a number of activities in the United States and Asia. Recticel aims to achieve sustainable, balanced added value and steady, profitable growth for the benefit of its customers and its shareholders. For Editorial Information: Jennifer Holzinger The Dow Chemical Company +1 989 636 8537 Piet Tytgat Recticel N.V +32 9 368 95 87 Tytgat.piet@recticel.com ®™^* Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow
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