Behind the Scenes: What It Takes to Bring Volara® to Market Every Day
Producing a high-performance foam like Volara® isn’t just about running equipment — it’s a daily commitment to precision, quality, and teamwork. At SEKISUI Voltek, every roll of foam that leaves our plant represents thousands of decisions, data points, and hands working together to deliver the consistency our customers rely on. From raw materials to final shipment, here’s a behind-the-scenes look at the people, processes, and technologies that make Volara® possible every single day.
It Starts with High-Quality Materials and Expertise
Volara® is known for its uniform cell structure, reliability, and performance — and that begins with the materials we source. Our process starts with carefully selected polyolefin resins, along with specialized additives that help create the physical cross-linking Volara is known for. But materials alone don’t make great foam. It also takes the expertise of our Engineering, R&D, and Production teams, who understand exactly how each formulation behaves throughout extrusion, irradiation, and foaming.
Precision Extrusion: Where the Foam Begins
The extrusion process requires a balance of science and skill. Resin pellets enter the extruder, where heat and pressure create the base sheet that will become Volara®. Our operators adjust temperatures, pressures, screw speeds, and line conditions in real time to maintain:
- Uniform thickness
- Sheet consistency
- Surface quality
- Proper density and weight
It’s a complex process — and it’s why our trained operators, with decades of combined experience, are one of Voltek’s greatest strengths.
Controlled Cross-Linking for Performance and Durability
Once extruded, the sheet goes through controlled physical cross-linking, a defining characteristic of Volara® foam. This step builds the durability and resilience engineers depend on for applications such as:
- Medical devices
- Tape and gasket materials
- Automotive interiors & EV components
- Industrial packaging
- Flooring underlayment
- Sports and leisure equipment
Precise cross-linking ensures that Volara® maintains its performance even in demanding environments.
Expansion: Creating Volara’s Signature Closed-Cell Structure
One of the most critical steps is the foam expansion process. Using carefully monitored heat exposure, the sheet expands uniformly to create Volara’s smooth, fine, closed-cell structure. This is where the magic happens — where density, thickness, and cell structure all come together. Our teams monitor each run and adjust as needed, ensuring customers receive the exact material performance they require.
Every Roll Is Tested — No Exceptions
Quality isn’t a department at SEKISUI Voltek; it’s part of every job. Every production run of Volara® is tested in our on-site laboratory before it ships, including:
- Density
- Tensile strength
- Elongation
- Compression set
- Tear resistance
- Cell uniformity
- Thickness and weight consistency
Our ISO 9001 processes ensure nothing leaves our facility without meeting customer and regulatory requirements.
Production Support, Scheduling, and Customer Service Keep Everything Moving
Behind every roll of Volara®, there’s a network of people who make sure the right product is produced at the right time.
- Production Scheduling aligns customer orders with machine availability.
- Maintenance ensures equipment reliability and uptime.
- Customer Service coordinates timelines, communicates customers’ needs and keeps them informed.
- Shipping & Logistics make sure every roll was packaged, labeled, and delivered accurately.
It’s a coordinated effort — and smooth operations are only possible because of clear communication and teamwork across departments.
Continuous Improvement Is Part of Our Culture
SEKISUI Voltek has a long history of Kaizen, lean, and continuous improvement activities. Every day, teams look for ways to:
- Reduce waste
- Optimize resin use
- Improve line efficiency
- Enhance product consistency
- Increase safety and training
- Strengthen sustainability practices
Bringing Volara® to Market Is a Team Effort
Every roll of Volara® reflects the hard work of the people behind it — the engineers, operators, lab technicians, maintenance teams, schedulers, customer service representatives, and shipping specialists who ensure consistency day after day.
Our customers count on Volara® to perform, and we take that responsibility seriously. It’s not just foam — it’s the result of decades of innovation, experience, and dedication.
