|Foam rubber mattress [Public domain], via Wikimedia Commons|
- Material preparation - Liquid and solid material generally arrive on location via rail or truck, once unloaded liquid materials are stored in heated tanks. When producing slabstock typically two or more polymers streams are used.
- Mixing - Open pouring, better known as continuous dispensing is used primarily in the formation of rigid, low density foams. Specific amounts of chemicals are mixed into a mixing head, much like an industrial blender. The foam is poured onto a conveyor belt, where it then cures for cutting.
- Curing and Cutting - After curing on the conveyor belt the foam is then forced through a horizontal band saw. This band saw cuts the pieces in a set size for the application. General contracting uses 4’x12’x2’’.
- Further processing - Once cut and cured the slabstock can either be sold or a lamination process can be applied. This process turns the slabstock into a rigid foam board known as boardstock. Boardstock is used for metal roof insulation, oven insulation, and many other durable goods.