polyurethane

change the company’s destiny takes place: polyurethane

The company was established in 1957 by the Rossetto brothers Angelo, Augusto and Narciso.
At the beginning the activity focuses on the manufacturing of unfinished wooden sofa frames.
In the ’60s a revolution that will change the company’s destiny takes place: polyurethane.
Constantly, production moves towards moulding of flexible, integral, rigid polyurethanes which nowadays still is the core business of the company. At present the second generation of Rossetto is leading the company.

Over the decades, the company’s facilities have grown and new machinery and state-of-the-art technologies have been adopted. The company covers 30.000 m2 of overall surface (15.000 indoor), employs more than 120 people and exports to 32 countries in all the five continents.

Our customers are chairs, armchairs, sofas and accessories manufacturers of the furniture (contract, office, home and communities), medical, naval, lighting sectors. Among our best accounts we can include the most renowned companies of the furniture industry like Tonon & C., Poltrona Frau, Moroso, Siltalnd, Segis, Calligaris, Gruppo Sintesi, Bonaldo, Arper, Casprini, Plank, De Padova, Poliform, Domitalia, Doimo, Boss Design, Allermuir, Senator, Züco, Walter Knoll, Jori, Ligne Roset.

Starting from a 3D file or a physical sample, we make the solid pattern (model) and the mould, we design the inner armature (if necessary) and mould it over with the most suitable polyurethane system.

In order to meet the more and more challenging requirements of the market, we offer seven different polyurethane systems. Please visit the following link POLYURETHANES for more information.

These seven PU systems are the result of many years of dedication and research in cooperation with our suppliers like Dow Chemical spa, Bayer International s.a., Europoliuretani srl.
These investments are still going on, so that we can always offer our customers the newest polyurethanes.

We invite you to contact us: we will be at your disposal for any further information you may need.
We will be glad to assist you concerning the feasibility and costing of your seating or accessory projects and suggest the right combination of inner armature (if necessary) and moulded polyurethane.

Our goal is to be a reliable partner and become irreplaceable for our customers by offering high quality products at competitive prices; the contribution to the success of your products is our biggest achievement.

wood

we manufacture inserts, chair, armchair and sofa frames, small tables, bed-heads and bed-cases, bases, legs and feet.

In this department, we manufacture inserts, chair, armchair and sofa frames, small tables, bed-heads and bed-cases, bases, legs and feet. We make use of solid wood only (beech, poplar, cherry, fir). We mainly produce:
Wooden inserts that are afterwards moulded over with our polyurethanes.
Sofa and armchair frames, sofa-bed frames, standard or custom-made tables.
Bases, legs and feet for chairs, armchairs and sofas.

production

The construction and maintenance of epoxy resin tools, which are employed for moulding the different polyurethanes

The construction and maintenance of epoxy resin tools, which are employed for moulding the different polyurethanes, is made here. The construction of aluminium tools is outsourced.
Tools may have a manual or an automated motion.
Tools are kept in custody in our “tool warehouse” and will enter production on customers’ request.

finishing and packing

In this department, the moulded pieces are cleaned, trimmed, threaded and packed.

In this department, the moulded pieces are cleaned, trimmed, threaded and packed.

The trimming phase is executed by hand with the utmost accuracy and with precision rubber machines and cutters. A special care is dedicated to packing to avoid any problem of crushing of foams during transport. For this purpose, a “packing sheet” is filled out for each item where we note down the type and size of cardboard box, the number of pieces per box, the additional use of foam slabs as shock absorbers, polystyrene cubes that are placed between one piece and another to preserve their integrity. Some of the items are nylon wrapped prior to packing into the box.

According to customers’ requirement, we pack into no-logo boxes or into boxes with customer’s logo (provided by customers).

development and production of models

Starting from a 3D file or a physical sample

Starting from a 3D file or a physical sample, we make the solid pattern (model) by either the traditional handmade method or by CNC machining centre: the latter ensures the utmost precision and symmetry. Once the pattern is done, the next phase is the construction of the tool for polyurethane moulding and of the metal armature (if necessary).

moulding of polyurethanes

In this department the moulding process (through injection) of the different types of polyurethane takes place.

In this department the moulding process (through injection) of the different types of polyurethane takes place.
Polyurethane is a thermosetting polymer, obtained principally from a mix of two components: Polyol and Isocyanate.
The mix is injected by means of foaming machines into a mould to get a pre-shaped piece, either finished or ready to be upholstered.
According to the selected formula, with specific parameters like ratio between Polyol and Isocyanate and processing conditions many types of foams can be obtained, which are different for density, hardness, fire retardant classification, use (see POLYURETHANES).
We primarily produce unfinished polyurethanes (raw foams), ready to be upholstered with leather or fabric, and finished polyurethanes which are ready to sell.
Moulding of flexible polyurethane Polflex
Moulding of polyurethane FreeForm

metalwork

In this department, we manufacture metal inserts (inner armatures), the bases of our armchairs and chairs and the welding jigs.

In this department, we manufacture metal inserts (inner armatures), the bases of our armchairs and chairs and the welding jigs. We mainly produce:
Metal inserts that are afterwards moulded over with our polyurethanes.
Metal bases and legs that afterwards can be chromed, painted or undergo a galvanic treatment.
Welding jigs of metal inserts.

quality control

A special attention is given to this task, from the qualification of suppliers to after-sale service.

A special attention is given to this task, from the qualification of suppliers to after-sale service.

There are written procedures for the qualification of the suppliers, the handling of customers’ and suppliers’ orders and for the after-sale assistance.
We carry out inspections on incoming goods and production processes, on finished products and on departing goods, on measuring tools.
We execute statistic analysis of the output and of the complaints in order to remove their causes.
Our products can be tracked; rejected pieces are univocally identified and put aside.
We methodically carry out quality controls.

We cooperate with Catas, an official institution, to attest the conformity of materials and of moulded items with the regulations of the different Countries.
Mechanical tests are carried out as well as tests about ignitability and surfaces.

woodwork

In our woodwork department we manufacture wooden inserts (inner armatures) that are moulded with our polyurethanes.

In our woodwork department we manufacture wooden inserts (inner armatures) that are moulded with our polyurethanes.
We attend to the engineering of the insert, the construction of the cutting jig, the mass production.
A special attention is given to the engineering phase of the insert like choosing the right type and dimensions of wood, the way of cutting, trimming, milling, planing, drilling, rubbing and to all other operations suitable to obtain an insert which must be structurally resistant, comfortable and economically competitive.
If necessary the inserts are completed, prior to moulding, with elastic straps.

metal

In our metalwork department we manufacture the metal inserts (inner armatures) that are afterwards moulded over with our polyurethanes.

In our metalwork department we manufacture the metal inserts (inner armatures) that are afterwards moulded over with our polyurethanes.
We attend to the engineering of the insert, the construction of the welding jig, the mass production. A special attention is given to the engineering phase of the insert like choosing the right type and dimensions of metal, the way of cutting, bending, punching, drilling, welding and to all other operations suitable to obtain an insert which must be structurally resistant, comfortable and economically competitive. If necessary the inserts are completed, prior to moulding, with elastic straps and with wooden strips or plastic profiles to staple the fabric.
Prior to moulding, the visible parts of the insert can be either painted, chromed or undergo a galvanic treatment.

polflex

polflex Polyurethane system suitable for production of cold cure foams for furniture, chairs, armchairs, cushions, office seats

polflex Polyurethane system suitable for production of cold cure foams for furniture, chairs, armchairs, cushions, office seats. Items in Polflex are ready to be upholstered with leather or fabric. The shape is 100% unalterable.
The moulding process is fully water blown based and does not employ expanding agents (no CFC).
Polflex is generally injected on a structure (insert, inner armature) that can either be made of metal, Polstrong (structural rigid PU), wood, plastic or a combination of these.
Moulding process employs epoxy resin or aluminium tools.
It has an average density of 50 kg/m3<br/><br/><pind>On request, it can be fire retardant in compliance with following standards: <br/><li>ITALIAN class 1IM :UNI 9175 (1987) – UNI 9175/FA1 (1994)</li><li>ENGLISH class: regulations 1988 n.1324 schedule 1, part 1 and Amendment n.2358 (1989), BS 5852 crib n.5.</li><li>FRENCH class M4 </li><li>Technical Bulletin 117, Section A Part I and Section D Part II.

polint

polintis a black or coloured polyurethane, suitable for moulding of seats, backrests, office chair

polintis a black or coloured polyurethane, suitable for moulding of seats, backrests, office chair armrests and components for dental, medical, automotive sectors.
Polint is generally injected on a structure that can either be made of metal (insert, inner armature), Polstrong, wood, plastic or a combination of these.
Moulding process employs epoxy resin or aluminium tools
It has an average density of 400 kg/m3<br/><br/><red>POLINT is only for customer’s exclusive design

painted POLSTRONG

It is a structural polyurethane that keeps the same features as POLSTRONG.

It is a structural polyurethane that keeps the same features as POLSTRONG.
It has a high mechanical and shock resistance. Moulding process employs epoxy resin or aluminium tools. After moulding, the surface is manually painted with a bi-component acrylic paint, glossy and very resistant. It is ideal for items with 4 to 10 mm thickness (shells, furniture accessories, chairs, bases). By request, various colours are available.
It has an average density of 600 kg/m3<br/><br/><red>PAINTED POLSTRONG is only for customer’s exclusive design

TECH

TECH TECH® is the result of the research and know-how of the staff of our R & S department.

TECH TECH® is the result of the research and know-how of the staff of our R & S department.
TECH® is a structural polyurethane, therefore it does not need any inner metallic structure.
TECH® is a high density material (600-700 Kg/m³) that enables to make any shape with very thin designs. Unlike plastics materials, it is possible to obtain different thicknesses, from some millimetres to some centimetres, in the same piece, keeping the visible surface free from “shrinking” effects. The surface can have bas-reliefs or be perforated.
TECH® has a high shock resistance, much higher if compared to traditional structural rigid PU, maintaining at the same time a good elasticity in terms of seating comfort. It has a good resistance to scratches too.
TECH® employs epoxy resin moulds in the moulding process, that need a preliminary investment which is much lower (approximately 1/20) than for a steel or aluminium mould for plastics.
TECH® is also two-coloured: the peculiar manufacturing technique enables to make, with the same mould, an item in a single or in two colours; moreover, the surfaces can be either smooth or embossed or both in the same piece.
TECH® can be co-moulded: it is possible to combine a piece made in integral soft PU together with the rigid structure, so to give the seating area a “padding” sensation. It can also be moulded in combination with serigrafic films.
TECH® is unique also in fire resistance analysis because it passes the following test methods: Italian Class 2, British Standard crib 7, French M4.
Following test report is available: accelerated ageing with lamp UV ASTM G 154-06 (outdoor agents). No other integral PU has ever passed these tests.
TECH® won the “INTERZUM AWARD 2009” as high product quality for combining innovative aspects of material, function and design.
All this makes of TECH® a trendsetter in structural polyurethanes for furniture<br/><br/><red>TECH is only for customer’s exclusive design.

FREE FORM advanced

is an evolution of FreeForm; it is a coloured integral polyurethane whose molecular structure is particularly resistant, this provides a “partly” structural quality

is an evolution of FreeForm; it is a coloured integral polyurethane whose molecular structure is particularly resistant, this provides a “partly” structural quality and allow for the manufacturing of seats and backrests without inner straps or metallic reinforcement parts; the framework within the polyurethane body is generally located only around the perimeter (which is positive in terms of comfort and costs).
Moulding process employs epoxy resin or aluminium tools.
It has an average density of 400 kg/m3.</p>
<pind>It is fire retardant according to the following standards: <br /><li>Italian Class 1IM UNI 9175 (1987) – UNI 9175/FA1 (1994)</li><li>British regulations 1988 n.1324 schedule 1, part 1 and Amendment n. 2358 (1989), </li><li>BS 5852 crib n.5.</li></pind><br /><p>Following test reports are available:
Resistance of colour to friction (EN ISO 11640:1998); accelerated ageing with lamp UV ASTM G 154-06 (outdoor agents).</p><br /><p><red>FreeForm Advanced is only for customer’s exclusive design.

FREE FORM

freeform is a soft and coloured integral polyurethane

freeform is a soft and coloured integral polyurethane with a nice sensation to the touch; it has a high mechanical resistance in terms of internal elasticity and scratch resistance. It is particularly recommended for production of seats for barstools, chairs, small armchairs.
FreeForm is generally injected on a structure (insert, inner armature) that can either be made of metal, Polstrong (structural PU), wood, plastic or a combination of these. Moulding process employs epoxy resin or aluminium tools.
It has an average density of 250 kg/m3<br/><br/><pind>It is fire retardant according to the following standards: <br/><li>Italian Class 1IM UNI 9175 (1987) – UNI 9175/FA1 (1994)</li><li>British regulations 1988 n.1324 schedule 1, part 1 and Amendment n. 2358 (1989), BS 5852 crib n. 5.</li><li>FRENCH M4</li><li>Cigarette Test: regulations 1988 n.1324 schedule 4 and Amendment n.2358 (1989)</li></pind><br/><p>Following test reports are also available:
Assessment of surface resistance to cold liquids (EN 12720/97); resistance of surfaces to cleaning products (PTP 53/95); resistance of colour to friction (EN ISO 11640:1998); accelerated ageing with lamp UV ASTM G 154-06 (outdoor agents).
A lot of well-known companies have developed their chairs using FreeForm, achieving great success in terms of sale volumes and image, so to display them in the most popular TV shows.<p><br/><red>FreeForm is only for customer’s exclusive design.