CONTINUOUS FOAMING

Continuous foaming is a method of foam manufacturing, when large production of foam is needed. A continuous foaming machine is a high-capacity equipment for producing a continuous slab of flexible PU foam with a desirable length.

In the continuous process, the foam rises within seconds after mixing the ingredients on a moving conveyor and then solidifies. In theory, foam blocks of several kilometers in length could be produced this way. In fact, the foam blocks are typically cut at a length of between 15 and 120 meters, cured and stored for further processing.

PROCESS

All the PU chemicals are first put together in a mixing chamber, and then taken into a metal trough and sprayer where the initial reaction takes place. The rising foam then passes from the top of the trough to a variable width fall plate, which then leads the expanding foam block along a metal slat conveyor for further expansion.

CONTROL

The machine is equipped with PLC Digital Touch Screen System and can be controlled over the internet for optimized production costs. The machine allows changing the formulation according to customer’s request, without stopping the machine, and with no need for test flow. The resistance degree can reach 3-5 international standards.

APPLICATIONS

The equipment is used for manufacturing soft PU products with densities between 8 and 70 kg/m3. The materials can be then used in industries such as upholstery, mattresses, packaging, shoes, cloths, electricals and automotive. Over 200 different formulas of foam can be saved, adjusted and changed at any time.

DESCRIPTION OF EQUIPMENT

METERING SYSTEM. There are 7 metering systems. All systems are equipped with world class AC motors, AC variable speed drives, internal gear pumps with low slippage, pressure gauges and recirculation network to ensure high quality final product.

FOAMING TUNNEL AND CONVEYOR. The tunnel construction forms a complete enclosure around the foam slab with top plates, side walls and conveyor slats. The conveyor is equipped with AC speed drive motor. Side walls can be adjusted from 0.98 m to 2.4 m.

TROUGH & FALL PLATE. They can be adjusted in height at various levels to ensure more flattop blocks. It is equipped with motors and gearboxes.

PAPER FEED & REWIND. There are 2 paper systems. The bottom paper feed reel is mounted in front of the foaming platform and is equipped with unwinding motor for automatic operation. Rewinding of the side papers is at the other end of the tunnel. The rewinding speed is self adjustable to synchronize with the conveyor speed.

CONTROL PANELS. This is attached at a convenient position on the foaming platform . It is equipped with all the necessary electronics, flow meters, pressure gauges, and AC variable speed drive motors.

BENEFITS

Continuous foaming machines offer numerous benefits for manufacturers, reducing costs and improving quality. Additionally, they ensure consistent foam density, enhance foam structure and uniformity, and minimize defects, leading to higher-quality foam products. Being fully automated, the equipment also provides a fruitful degree of protection and safety, reducing to a minimum both human and process-related accidents.

TECHNICAL ASSISTANCE & SUPPORT

You can access SERVICES, for more details about our ability to provide you with technical assistance or full technical support, in any effort to implement a new investment, project development, installation and commissioning of machines, operator training and best practices production.

If you access REFERENCES, you can discover projects for which we were asked to install and commission various machines. Our high responsiveness to your needs and good availability for any assistance or support you need are already recognized by our partners and recommend us as a reliable support for your business.