Practical Data Center Airflow Management Solutions Built on Formex Safety

Heat has always been the silent constraint of data center performance. As rack densities climb and power envelopes tighten, airflow mistakes that were once tolerable now show up as higher PUE, stranded cooling capacity, and avoidable risk.

For more than 40 years, Formex has focused on one mission—protecting people, power, and equipment through flame-retardant electrical insulation. That same safety-first engineering mindset is now being applied directly to the airflow challenges modern data centers face every day.

PlenaForm^® Air Baffles

In raised-floor environments, the plenum is either an asset or a liability. In our experience working with high-density deployments, uncontrolled under-floor airflow is one of the fastest ways to lose static pressure and cooling effectiveness.

PlenaForm^® Air Baffles create defined airflow paths under the floor, preventing cold air from short-circuiting back to returns and ensuring it reaches the equipment that needs it.

Directs cold air precisely to high-load zones
Reduces hot/cold air mixing under the floor
Supports measurable data center PUE reduction
Manufactured with flame-retardant Formex material for added safety

PlenaFill^® Blanking Panels

Bypass airflow is one of the most underestimated inefficiencies in a data center. Empty U-spaces allow conditioned air to pass straight through the rack without doing any work, while hot exhaust air recirculates to the server intakes.

PlenaFill^® Blanking Panels seal unused rack space, forcing air through the equipment instead of around it.

Prevents bypass airflow and hot air recirculation
Optimizes equipment life by reducing overheating
Improves server inlet temperature consistency
Increases effective output of existing CRAC/CRAH units
Flame-retardant construction supports fire-safe data center design

PlenaForm^® Cable Tray Liner

Disorganized cabling increases fire load, complicates moves, adds, and changes (MACs), and creates the familiar “spaghetti” appearance that no operator wants to explain during an audit.

The PlenaForm^® Cable Tray Liner installs inside basket trays to create a continuous bottom surface that supports structured cable bundles. The result is cleaner routing, improved load distribution, and a safer, more manageable overhead pathway.

Improves cable organization and load distribution
Simplifies routine MACs without modifying existing trays
Enhances visual cleanliness and audit readiness
Reduces cable sagging and stress within basket-style trays which further supports signal continuity

Why Formex

Safety

For over 40 years, Formex has engineered flame-retardant insulation materials for safety-critical applications. That same safety-first mindset now extends into data center infrastructure, where fire risk mitigation is fundamental.

Reliability

Formex is backed by experienced teams and disciplined processes that customers can depend on. From application support to production consistency, we deliver predictable outcomes in always-on environments.

Solutions

Formex delivers more than insulation materials. With integrated offerings such as PlenaForm^® and PlenaFill^® products, we apply material science to solve real, physical challenges in data center environments.

Compliance

Formex materials are engineered to meet stringent regulatory requirements, including UL 94 V-0 flame retardancy and RoHS compliance. This enables efficiency improvements without compromising audit readiness or regulatory alignment.

Continuity

Formex works closely with customers to support evolving needs over the life of their infrastructure. Our long-term partner mindset helps turn current challenges into solutions that remain relevant as requirements change.

Take the Next Step Toward Safer, More Efficient Airflow and Cable Management Solutions

Visit PlenaForm^® website for more information or Contact us to discuss your airflow challenges with a specialist.