 
Reducing foam waste, making great savings.
TRC Mathematical Modelling has worked together
with the Dunlop Foams Group to reduce the foam wastage
in processing operations. Foam is produced in large blocks that are subsequently converted into smaller
products, such as cushions and mattresses. In the cutting process, there is about 25% wastage, as the
smaller items do not pack perfectly into the large block. TRC Mathematical Modelling (a commercially
focussed centre at the University devoted to solving industrial problems involving modelling, measurement
and performance) developed algorithms that are able to pack the items more efficiently and reduce the
wastage by approximately 5%.
The main technique behind this improvement is optimisation, but statistical modelling also played
a key role in determining which offcuts should be kept for later use and which should be discarded.
The benefit to Dunlop Foams is a reduction in raw material usage and production requirements, that will
yield estimated savings of around $800,000 per annum.
For more information go to TRC
Mathematical Modelling.
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