TOACELL™ is a new innovation in Supercritical Foam, elevating the benchmark for sustainable physical foam solutions.

TOACELL™ is elevating the benchmark for sustainable foam solutions. 

How TOACELL™ is made

STAGE 1

CO2 Gas

Polymer Resin

STAGE 2

Heat and Pressure

TOA-Resin and gas saturation.

STAGE 3

Cell Creation

Closed-Cell bubbles form and expand

STAGE 4

TOACELL™ Foam

The TOACELL™ Advantage

TOACELL™ is a range of closed-cell foam made using a process called Supercritical Physical Foaming. Delivering exceptional lightness, superior thermal insulation, and remarkable durability while setting a new standard with TOTO-TOA®’s Bio-Adaptive™ Technology.

  • TOACELL™ maximises recyclability, aligning with circular economy principles. TOACELL™ is a thermoplastic and can be easily recycled.

  • TOALITE™ is adapted to naturally breakdown back into nature in both active aerobic and anaerobic conditions, such as landfills and soil environments. (Active means that bacteria and microbes are present and eating resources.)

    TOALITE™ ensures durability throughout its intended use by avoiding degradation during storage, use, or exposure to sunlight or rain when not in contact with soil.

  • Being both recyclable and able to naturally breakdown back into nature helps lessen ecological damage.

  • TOACELL™ is versatile, enabling innovative designs for products that adhere to strict industry standards while being environmentally friendly.

  • TOACELL™ surpasses thermoset foams by offering superior quality, lightweight strength, enhanced thermal insulation, and better impact resistance. Its ability to be recycled further adds to its advantages, promoting a more sustainable option for a wide range of applications.

TOACELL™ Features

LIGHTWEIGHT

Can achieve very low density and low weight

CIRCULARITY

Highly recyclable due to no chemical foaming agents

RESILIENT

Excellent resilience, and returns to its original shape after stress and impact.

TREMPERATURE STABLE

High and low temperature resistance. Great insulation properties

EXCELLENT CUSHIONING

HIGH TENSILE STRENGTH

GOOD CHEMICAL RESISTANCE

BIO-ADAPTIVE™ TECHNOLOGY

THOROUGHLY TESTED

TOACELL™ Applications

TOACELL™ is the eco-friendly alternative to thermoset foam for a wide range of applications including:

  • Excellent thermal insulation properties for use in building thermal and sound insulation, refrigeration units, and industrial applications.

  • Excellent versatility as a replacement for all foam components used in sports, leisure, and footwear applications.

  • Can be used in various applications, from comfort to weight reduction.

  • Excellent cushioning and protection for shipping and handling of delicate and fragile items.

  • Excellent temperature stability, lightweight, and strength make TOACELL™ great for aerospace and military applications.

Overall, TOACELL™ is an extremely versatile material that can be used in various industries and applications due to its adaptable properties and capabilities.

TOACELL™ Range

TOACELL™ is an expansion of the TOA-Resin family of materials. Available in:

  1. TOA-TPU

  2. TOA-EVA

  3. TOA-PP

TOACELL™ foams are designed to be more environmentally friendly, offering better recyclability options in both the production and end-of-life stages.

TOACELL™ vs Thermoset Foams

TOACELL™ foams are designed to be more environmentally friendly, offering better recyclability than thermoset foams.

TOACELL™ foams are made by applying heat, pressure, and abundant gases found in the air, such as N2 and CO2, to expand, forming a uniform foam structure. Resulting in foams with very fine and uniform cellular structures, enhancing their strength and thermal insulation properties. This makes TOACELL™ foams a greener choice for applications requiring lightweight, durable materials.

 

In contrast, thermoset foams use chemical compounds as the foaming agent, and once set, they cannot be remelted.

What makes TOACELL™ more recyclable than Thermoset foams?

TOACELL™'s thermoplastic nature allows it to be remelted and reshaped multiple times, facilitating recycling and reducing landfill waste.

Common thermoset foams like PU (Polyurethane) and EVA (Ethylene-Vinyl Acetate) foams are permanently set and cannot be remelted or recycled easily, often ending up as environmental pollutants.

Sustainability

Our commitment to sustainability is not just about reducing waste but also about contributing to a circular economy, where materials are reused and repurposed, minimising environmental impact.

TOALITE™ highlights the importance of choosing the right materials that support eco-friendly manufacturing and disposal practices.

  • Using a global network of foam processors using our proprietary ingredient blends, we have built a scalable infrastructure to supply low and high volume demand.

    We have our own processing partner facility throughout China for processing our TOACELL™ foams to sheets and custom made parts

  • Our TOACELL™ foams are produced with advances in processing techniques using gas and high pressure instead of chemical compounds used in conventional foaming processes. This makes our TOACELL™ more environmentally friendly and recyclable.

    Most foams are thermoset, while TOACELL™'s thermoplastic nature allows it to be remelted and reshaped multiple times, facilitating recycling and reducing landfill waste. All TOACELL™ grades benefit from TOTO-TOA®’s Bio-Adaptive™ Technology.

  • TOTO-TOA® offers a paid sampling program allowing brands and manufacturers to sample in small to medium size volumes. Samples can be procured rapidly in sheets. For larger sampling requests or custom parts, please contact sales@toa.eco

  • TOTO-TOA® makes TOACELL™ available globally thanks in part to our team's experience in moving raw materials internationally out of our networks in the far East. Contact us at sales@toa.eco to learn more about availability and growing network of hubs 

FAQs: TOACELL™