Innovation at NEVEON: the engine that drives us

Zgierz / Poland: 
PU Pilot Plant and PU Analytics Lab

The heart of our R&D hub beats in Zgierz (Poland). In our PU Innovation Pilot Plant, we test new PU foams and raw materials under realistic conditions. Instead of starting large, resource-intensive productions, we develop test foams with volumes of between one and three cubic meters. This makes development more flexible, more cost-effective - and above all more sustainable. Here we can boldly break new ground, test high-risk ideas or customized foams for special customer requirements. 

Maciej Ratajczyk, our Team Leader Advanced Materials, sums it up perfectly: “In our PU pilot plant, we test new foams and raw materials on a small to medium scale under realistic production conditions – saving time, costs, and resources.” 

Right next door, our new PU Analytics Lab ensures that the highest quality is not left to chance. Here we test chemical properties, emissions and raw materials directly in-house. This not only gives us control over the quality of each individual product, but also over the entire supply chain - from the first raw material to the finished foam product. This is particularly important for sensitive applications such as mattresses or vehicle interiors. 

Michał Włodarczyk, Chemik Analityk at NEVEON, describes the advantage as follows: “With our expanded analytics lab, we now have even greater control over the quality of the raw materials used and the products manufactured from them.”

Linz / Austria: Data Science & Simulation and Prototyping & Testing

While the raw materials are being tested and perfected in Poland, we are harnessing the power of digitalization in Linz. In the Data Science & Simulation department, we test materials long before the first foam block is produced. Simulations help us to predict material behaviour, identify optimization potential at an early stage and precisely calculate the carbon footprint of new products. This results in more sustainable, more efficient solutions right from the start. 

Christoph Gruber, Team Leader Data Science, describes it like this: “Data science provides us with valuable insights for better, more sustainable products. Simulations reveal optimization potential early – even before production begins.”

But theory alone is not enough. Every idea is put through its paces at the Prototyping and Testing Center in Linz. Whether mechanical resilience or long-term behavior - this is where the wheat is separated from the chaff. Only what passes the tests makes it to the next phase. We also experiment here with new manufacturing processes and functions, such as integrated sensor technology in aircraft seats. 

Alexander Maier, our Head of Physical and Mechanical Testing, sums up the approach aptly: “Through precise testing procedures, we optimize resource use, detect weak points early, and improve new designs in a targeted way during prototyping.”