Manufacturing of PUR specialty sponges and foam cut-to-size parts for ceramics, glass, optics, filtration and industry.
Zervos GmbH & Co. KG
Dießen/RiederauNew on Amplifa
The history & philosophy behind ZERVOS
Zervos GmbH & Co. KG manufactures industrial specialty sponges made of polyurethane foam (PUR) as well as cut-to-size parts at its site in Dießen/Riederau in Bavaria. The product range comprises cut-to-size parts and hand wiping sponges, oval sponges, sponge rollers (outer diameter 60–350 mm, inner diameter 4–145 mm), sponge bands as custom-made special products for machine sponging, sponge wedges as well as flexible foam filters for extraction and plasma systems and sponge inserts for adsorption filters. Materials processed include open-cell flexible foams (HS, HN, HF, ESRH, RSRT), rigid foams (TS), reticulated sponges as well as ester and ether foams. The focus is the porcelain and ceramics industry, which Zervos has served since the 1980s as a producer of PUR specialty foams; further industries include the glass and optical industries, gastronomy (filtration technology), the electrical industry, wood and metal processing as well as leather-processing businesses. Production is flexible – from large-volume runs to smaller quantities, with cutting tolerances of less than one millimetre for by-products. The company traces back to a sponge trading firm founded in Greece in 1869.
- Site
- Dießen/Riederau
- Processes
- Manufacture of PUR sponges (polyurethane foams), Dimensionally accurate cut-to-size cutting of PUR sponges, Cut-to-size parts / hand wiping sponges, Manufacture of oval sponges, Manufacture of sponge rollers (machine processing of porcelain and ceramics), Manufacture of sponge bands (custom-made special products for machine sponging), Manufacture of sponge wedges (sponging wedges), Flexible foam filters for plasma systems (exhaust air systems)
- Materials
- Polyurethane foam (PUR), Flexible foam HS, Flexible foam HN, Flexible foam HF, Flexible foam ESRH, Flexible foam RSRT, Rigid foam TS, Reticulated sponges (open-pore)
- Founded
- 1869
- Industries
- Porcelain and ceramics industry, Glass industry, Optical industry, Gastronomy, Wood and metal processing, Leather-processing industry
- 01
PUR foam raw material purchasing
- 02
Foam processing
- 03
Dimensionally accurate cutting / circular cutting
- 04
Quality control
- 05
Shipping
Foams & processes
Flexible foam HS
Natural light-coloured, heavy, grippy material for high stress in cut-to-size parts, oval sponges, wedges and flexible foam filters.
Flexible foam HF
Fine, soft material for hand wiping sponges and gentle wet processing of porcelain and ceramics.
Flexible foam HN
Medium-firm, yellow material (F/M/G) for cut-to-size parts, oval sponges and flexible foam filters.
Flexible foam ESRH
Fine-celled flexible foam for fine finishing of ceramic surfaces.
Flexible foam RSRT
Fine-celled flexible foam for fine finishing of ceramic surfaces and application of polishing and care agents.
Rigid foam TS
Open-cell abrasive rigid foam for deburring raw ceramics.
Reticulated sponges (open-pore)
Open-pore reticulated sponges (45 ppi, 35 ppi) for dry wiping/sponging.
Ester foams
Densities 18–60 kg/cbm with regular cell structure and good shock absorption.
Ether foams
Densities 16–80 kg/cbm with open cell structure and high elasticity.
Sponge foams
Natural-sponge-like cell structure with high tear strength for specialty sponges.
Natural sponge
Historically imported and processed natural raw material, the foundation of the company's founding.
Locations
Dießen/Riederau
DEHeadquarters / Production
- Lot size
- Large-volume runs down to smaller quantities
- Materials
- PUR flexible foams, rigid foams, reticulated sponges
Products & components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of PUR sponges (polyurethane foams)Plastics | – | – | – | Large-volume runs and smaller quantities | Polyurethane foam (PUR) |
| Dimensionally accurate cut-to-size cutting of PUR spongesPlastics | less than 1 mm deviation possible (by-products) | – | – | – | Polyurethane foam (PUR) |
| Cut-to-size parts / hand wiping spongesPlastics | – | – | – | – | PUR flexible foam HS, PUR flexible foam HF, PUR flexible foam HN F/M/G, PUR rigid foam TS |
| Manufacture of oval spongesPlastics | – | – | – | – | PUR flexible foam HS, PUR flexible foam HN |
| Manufacture of sponge rollers (machine processing of porcelain and ceramics)Plastics | exactly round-running up to outer diameter 180 mm, from 190 | Outer diameter 60 – 350 mm × Inner diameter 4 – 145 mm | – | – | PUR foam |
| Manufacture of sponge bands (custom-made special products for machine sponging)Plastics | – | – | – | – | PUR foam |
| Manufacture of sponge wedges (sponging wedges)Plastics | – | – | – | – | PUR flexible foam HS |
| Flexible foam filters for plasma systems (exhaust air systems)Plastics | – | – | – | – | PUR flexible foam HS/HN/HF |
| Sponge inserts for adsorption filtersPlastics | – | – | – | – | PUR foam |
| Deburring of raw ceramics (with open-cell rigid sponges)Surface | – | – | – | – | PUR rigid foam TS |
| Wet sponging / post-finishing of porcelain and ceramicsSurface | – | – | – | – | PUR flexible foam HS/HN/HF |
| Dry wiping / sponging (45 ppi, 35 ppi) with reticulated spongesSurface | – | – | – | – | Reticulated sponges (open-pore) |
| Processing of natural spongesPlastics | – | – | – | – | Natural sponge |
Additional services
Reference customers
History
- 1869
Founded in Greece with its own fleet of sponge diving boats; import and processing of natural sponges.
- 1970er–1980e
Decline in the availability of natural sponges; switch to the production of polyurethane foams (PUR sponges).
- 1980er
Establishment as a leading producer of PUR specialty foams for the ceramics industry.
- 1990er
Support of the ceramics industry's transition to flow-line production and takt lines; development and equipping of new production systems.