Woodbridge Foam Corporation Business Report up until FY ended Dec. 2014
Technological Alliance
-In 2012, TrimTech Interior Soft Trim Solutions, a business unit of the Company, announced a global cooperation with Multimatic, a Canada-based manufacturer of automotive mechanisms, to provide product design, engineering, prototyping and manufacturing of automotive trim solutions. TrimTech Solutions produces head restraints, armrests, bolsters and closure panels. In accordance with this cooperation, TrimTech Solutions launched a new product offering called HeadSmart head restraint mechanism technology, which provides full design capability, including flip and fold seats, active head restraints systems and automatic and manual release applications. (From a press release on October 23, 2012)
-In 2012, the Company announced that it recently licensed the Company's StructureLite technology to JSP, a Japanese supplier of plastic foams, to market and produce expanded polypropylene (EPP) seat frames in Japan. StructureLite seat frame technology replaces traditional steel stampings and wires frames and can lower seat system weight by up to 35%. This technology was previously licensed by JSP for manufacture in North America. (From a press release on January 9, 2012)
Product Development
TrimVisible LE low emission molded foam technology
-In 2014, the Company announced its TrimVisible LE low emission molded foam technology. The recent development of TrimVisible LE foams enables the Company to meet extremely low volatile organic compound (VOC) test requirements. As tested through an independent accredited laboratory, the use of TrimVisible foams provides up to an 80% reduction of certain volatile compounds without compromising seat cushioning performance. (From a press release on January 17, 2014)
StrataLiner lightweight composite boards
-In 2014, the Company developed StrataLiner 3D lightweight composite boards that are used to manufacture automotive headliners and a variety of interior parts including load floors, deck lids and package trays. The polyurethane composite boards are manufactured by laminating engineered reinforcement layers to custom formulated polyurethane substrates, providing superior rigidity in a product that is up to 35% lighter than the leading competing material. (From a press release on January 15, 2014)
StrataPlush HD coverstock laminate foam
-In November 2013, the Company completed development of its StrataPlush HD polyurethane flexible laminate coverstock foam technology. It has all the benefits of standard StrataPlush foams, while also providing superior resistance to mottling, higher firmness range and reduced thickness opportunity as low as 2 millimeters. This coverstock laminate foam innovation is designed to be used in a variety of automotive interior trim applications including headliners, seats, head restraints and arm rests. (From a press release on November 15, 2013)
TDI high-resiliency foam
-In September 2013, the Company announced the development of its new low-mass TDI high-resiliency foams for automotive seating applications. This new TDI HR foam can be formulated to precisely match the vibrational response of any MDI foam over an expanded density range. This enables TDI seating foams to provide higher resiliency, lower hysteresis and superior durability, while delivering significant reduction in mass. Another benefit of this new TDI formulation is its ability to improve cabin air quality and reduce windshield fogging due to the ultra-low volatile organic compound characteristics of the foam products. (From a press release on September 17, 2013)
Foam material for car seats
-In June 2013, the Company completed development of a new foam material for car seats. This new foam allows the Company to create a seat design template for different types of vehicles such as sedans and compact cars. The new foam has improved vibration absorption characteristics and reduced weight compared to a previously developed version. As many automakers have started to use common seat frames, the Company expects a nearly 20% cost reduction for a single seating unit if the new foam for seat cushioning is introduced as a standard. Furthermore, by using the new foam as a standard, seat design and production costs will be lowered as manufacturers can reduce the work needed to optimize the suspension for each vehicle model due to the improved vibration characteristics. An additional benefit of the foam is improved ride comfort for passengers. (From an article in the Nikkan Jidosha Shimbun on June 20, 2013)
WhisperTech flame retardant foam
-In June 2012, the Company announced the development of a new flame retardant foam called WhisperTech V0, for a range of under-hood acoustical and thermal insulating applications to meet UL-94 V0 flammability requirements. This new material represents a significant development in flammability performance for Noise, Vibration and Harshness (NVH) solutions, offering enhanced sound absorption and transmission loss properties versus competing materials including metals and engineered fibers. These flame retardant formulations are available for a wide range of molded components that make contact with the engine including: covers and various acoustical insulators for manifolds, valve and cam covers, fuel rails, air intakes and pumps. Additionally, these products can integrate fasteners and mounting brackets for ease of assembly. (From a press release on June 13, 2012)
TrimTech interior soft trim product line
-In February 2012, the Company announced several new products under its TrimTech interior soft trim components product line. These products include the ComfortZone dual hardness head restraint; DecoSkin alternative trim technologies; TrimLine components for thin profile parts; and TrimStyle components for complex geometries and tight dimensional tolerances.
StrataTrim polyurethane composite board
-In January 2012, the Company announced the development of StrataTrim polyurethane composite board technology. Applications for StrataTrim include: load floors, deck lids, package trays, sun shades and seat backs. StrataTrim advantages include: system cost savings, superior design flexibility, enhanced surface quality, improved acoustics, up to 50% mass reduction, glass and glass-free reinforcement options, low cost composite tooling, shortened tool lead time, quick prototyping and a cost effective production option for low volume programs.
ComfortSense seat cushioning
-In January 2012, the Company announced that it developed new ComfortSense seat cushioning which delivers improved initial softness without the added expense of a secondary topper pad. ComfortSense A-surface treatments also deliver optimized air distribution capability in both active and standard seat systems. (From a press release on January 16, 2012)
Investments outside Canada
-In 2014, the Company announced that it will open a new manufacturing facility in Capivari, Sao Paulo, Brazil. This facility will be the Company's sixth facility in Brazil. The Capivari facility will offer molded polyurethane technologies, produce high performance automotive seat cushions and interior parts such as head restraints and arm rests. With two OEMs announcing plans for new assembly plants in the region, the Company hopes that its new plant will be able to capitalize on the opportunities provided by the expansion. (From a press release on November 10, 2014)
-In 2014, the Company announced that its Formed Plastics division will expand its particle foam operations in Germany. The Company and its joint venture partners currently have particle foam manufacturing facilities in the U.S., Canada, Mexico and France. (From a press release on January 16, 2014)
-In 2013, the Company announced that its Formed Plastics division has expanded their growing business unit with a new particle foam facility in Chattanooga, Tennessee, U.S. Formed Plastics is a tier 1 particle foam and polyurethane foam solutions provider which manufactures cargo storage, seat frames, occupant safety and acoustical components from materials such as EPP, PEPP, EPE, and EPS. The Formed Plastics footprint expansion is a strategic complement to the Company's facilities in Kitchener, Canada; Leon, Mexico; and Trilport, France. (From a press release on May 21, 2013)
Data
-As of May 29, 2015, according to the Company's website, the Company has over 8,000 employees.