Custom polyurethane (PU) mouldings and stillages

The Bluestar manufacturing facility has a department dedicated to Polyurethane (PU) moulding.

Polyurethane is a class of polymers which is produced using a variety of chemicals. This unique makeup means that PU is an incredibly versatile material used in a range of applications from steering wheels to shoe soles and clothing to stillage inserts.

This gives businesses the ability to move away from using unoptimised, standard stillages and allows for storing the highest number of products or parts with high storage density.

I've collaborated with Bluestar on several transport and storage solutions, the design prototypes are exceptional.

Trusted by companies all across the UK

What is PU?

Polyurethane (PU) is a category of polymer plastics that is produced by reacting an isocyanate with a polyol. Using varieties of isocyanate we can create different forms of PU.

We offer 40A, 60A and 90A Shore PU – encompassing a balanced range of soft and flexible (40A Shore) to hard and rigid (90A Shore). We also offer D Shore polyurethane for customers that require a product with little flexibility.

Why should I use polyurethane dunnage in my stillage?

PU is an incredibly versatile material making it perfect for securing your components in stillages and euro pallets.

Our PU mouldings are durable and resistant to impacts and erosion, ensuring your goods remain protected during transit.

Benefits of using polyurethane dunnage

Using PU dunnage has a range of benefits, including:

Custom protection

One of the best features of PU dunnage is that it can be customised. It can fit the exact shape and size of the products it protects. This level of precision ensures a snug and secure fit, reducing the risk of damage during transit. Whether you are shipping fragile electronics or unusual parts, PU dunnage can be customised to fit your needs.

Shock absorption

PU dunnage is an excellent shock absorber. It excels at cushioning fragile items and dissipating impact forces. This means that even if there is rough handling during shipping, your products remain safe and intact.

The great shock absorption of PU reduces the need for extra packaging. This saves money and helps the environment.

Reusability and durability

Unlike many traditional packaging materials, we design PU dunnage to last. It can withstand multiple uses and continues to provide reliable protection over an extended period. This long-lasting quality saves you money over time, meaning you won’t have to keep replacing packaging materials.

Resistance to environmental factors

Polyurethane dunnage is resistant to moisture, chemicals, and solvents. This makes it suitable for a wide range of industries, including those where exposure to harsh conditions is common. Your products remain shielded from external elements, maintaining their quality and integrity.

Sustainability

In an era where sustainability is a top priority, PU dunnage shines. Some formulations are eco-friendly and recyclable, contributing to a reduced carbon footprint. You can align with green initiatives while enjoying the benefits of a reliable packaging material.

Cost-efficiency

Ultimately, the efficiency of shipping and packaging operations boils down to cost-effectiveness. PU dunnage reduces costs in several ways:

Fewer damaged goods mean fewer replacements and refunds
Reduced need for additional packaging materials
Long-lasting dunnage reduces the frequency of repurchasing

Read more about PU and what it can do for your business in our case studies below or get in touch to discover how we can help.

Read our case studies

Here, we showcase how businesses from diverse industries have leveraged our services to achieve remarkable production results.

Focusing on maximising transportation space, we created a 3D model of a large articulated lorry loaded with our fully custom stillages.

This showed JCB how our products help to increase the amount of room in a lorry and how to help reduce the number of trips needed to carry the same amount of parts.

We work on providing cutting edge transport and storage solutions for automotive giants McLaren.

Taking advantage of our polyurethane moulding and insert department, McLaren specify a variety of different measurements via thorough designs.

We take these and provide a fully bespoke output featuring the highest-quality materials and levels of production.

Lotus supplied us with CAD data for parts to be stored in one of our bespoke stillages. We designed a fully customised solution around the CAD drawings.

Taking this brief, we’ve completed thorough drawings and designed how the stillage will look.

With prototypes provided and approval secured, the bespoke stillages have revolutionised both transport and storage for Lotus.

Lotus

Lotus supplied us with CAD data for parts to be stored in one of our bespoke stillages. We designed a fully customised solution around the CAD drawings.

Taking this brief, we’ve completed thorough drawings and designed how the stillage will look.

With prototypes provided and approval secured, the bespoke stillages have revolutionised both transport and storage for Lotus.

Our Services

CAD Design

CAD software allows our stillages to meet every characteristic of a project’s requirement, every time.

3D Printing and Modeling

3D printing of product inserts and product pieces help stillage manufacturers to reduce lead times of their shipments with quick turnarounds of prototypes.

Polyurethane Mouldings

Eliminating elements of risk for valuable or fragile parts, having PU fitted inside the stillage is a perfect way to minimise movement of your parts during transportation.