How DEHUM Dehumidifiers Have Revolutionised The Foam Drying Industry

July 2, 2024

Foam is a material with more applications than you may realise. It’s not just for pool toys and padded seats but can be used on a much larger scale. One of the biggest applications is carpet underlay, where foam is used to improve the comfort, durability, and acoustic performance of a wide range of floors.

However, as useful as foam is, drying it can be a major hurdle, and one that flooring companies struggle to overcome. That’s where we come in. Dehum have revolutionised foam drying, making it the perfect material to work with.

But before we get to that, let’s explore the underlay industry a little more.

The Importance of Underlay in Flooring

Underlay, also known as underpadding or carpet padding, is a layer of material placed between the floor and the carpet. Most carpeted floors use underlay, even in domestic settings. Here’s why:

First off, comfort. Carpets without underlay feel thin and cold, without the slight sponginess you take for granted until you live without it. With a quality foam underlay, the carpets become nice and soft underfoot.

Next, insulation. With increasing energy bills hovering over our heads, it’s important to make sure our homes are as well-insulated as possible. A carpet underlay has improved thermal insulation, which retains heat in winter and keeps us cooler in the summer.

Noise reduction is another use that’s easy to take for granted. A carpet alone barely reduces sound, both above and below the floor, whereas the absorbent nature of foam underlay makes it much easier to get some peace and quiet. This is most important for hotels, care homes, and other large buildings where people don’t want to be disturbed.

Durability is important too. Even in buildings without much foot traffic, the floor will suffer wear and tear over time. If the floor is carpeted, this wear isn’t obvious, making it more important to preserve it. A carpet underlay protects the floor, improving its appearance and extending its lifespan.

Last but not least, carpet underlay is essential for moisture protection. Spillages on carpeted floors are a pain, and the issues continue even after the stain has been removed. Underlay acts as a barrier against moisture, so it doesn’t damage the floor.

Types of Underlay Material

There are four main types of underlay materials, each with their own strengths and weaknesses.

Foam Underlay – Foam underlay is lightweight and provides unmatched comfort, making it the go-to for residential settings.

Rubber Underlay – Rubber underlay is the best for commercial spaces, as it has the best acoustic performance and high durability that is great for high-traffic areas.

Felt Underlay ­– Felt underlay is made from recycled fibres, with excellent thermal insulation. This is the best option for wooden floors that aren’t good at absorbing heat.

Cork Underlay – Cork underlay is naturally resistant to mould and mildew, so it is ideal for hardwood and tile floors. It is also the most eco-friendly option if you are concerned about your carbon footprint.

Out of these four types, foam underlay is by far the most popular. This means there is high demand for quality foam underlay. However, there is an issue that can make this type of underlay tough to produce.

The Challenge of Foam Drying

Traditionally, foam drying is a lengthy process, especially for carpet underlay. Foam underlay takes almost a week to dry before the next stage of the manufacturing process can begin. This is a huge bottleneck and is only part of the problem.

To dry properly, the underlay needed large amounts of space to dry in. This means extra warehousing costs and you have to move other products or dry foam around to compensate.

You don’t have to take our word for it either. This is exactly what Interfloor, a client we have worked with for over 7 years, was dealing with. Production was far slower than it should’ve been, so they turned to us for a solution.

Dehumidification Solutions for Underlay Foam Drying

We specialise in coming up with bespoke dehumidification systems for clients. With us you don’t get ‘off-the-shelf’ products, you get a system that’s perfect for you.

So when Interfloor approached us with a challenge, we were ready and waiting. We examined their operation and soon had an idea that would change the flooring industry overnight.

We designed specialist drying equipment that utilised warm, dry air, circulating it constantly to remove moisture from the foam. Our innovative approach reduced the drying time from five days to a minute and a half, yes you read that right!

It an increase in efficiency so massive it’s hard to get your head around.

Here’s the impact our dehumidification solution had:

• Increased Productivity – The drastic reduction in drying time made production much faster overall, so more foam could be produced in much less time.
• Cost Savings – The overall cost was reduced in two ways. Firstly, our system used a lot less energy than traditional drying methods. Secondly, the need for less warehouse space made storage cheaper and easier, even with the addition of drying rooms.
• Improved Product Quality – You may think that faster drying made the foam poorer quality, but the opposite was the case. The fast-dried foam was higher quality than Interfloor had been able to produce previously. This was due to how our system dried the foam consistently every time.

As news got out about this new innovation, we were soon approached by other carpet underlay manufacturers who wanted to maximise efficiency the way Interfloor had. Well, we were more than happy to supply them with their own bespoke drying equipment, all tailored to suit their operation.

Other Applications for Drying Solutions

It isn’t just flooring companies that can benefit from our drying systems. Here are some of the industries that we provide drying solutions for:

• Automotive
• Aviation
• Electronics
• Food & Drink Manufacturing
• Healthcare
• Pharmaceuticals
• Utilities
• Wind Farms
• And more!

Essentially, if there is a product that needs to be dried or processed in a clean, dry environment, we have the perfect solutions. Advanced dehumidification is the modern way to do things; just because the existing solution works, doesn’t mean it can’t be improved.

With decades of experience in multiple sectors, we can see inefficiencies where you may see consistent results. When we meet with you to establish your needs, we will outline what we can offer, with evidence collected from our previous applications.

If you aren’t sure whether dehumidification can transform the way you work, please get in touch. We’ll conduct an in-depth site survey; if there’s any bottlenecks in your operations, we’ll find them and provide a new solution that will help you soar past your competitors.

You can contact us by calling 01926 882624 or check out our website www.dehum.com for more information.

We look forward to hearing from you.