PU Box Foaming Full Production Line Solution & Technical Specs
This complete batch-type foaming system is provided by Haifeng Polyurethane Machinery. Specially designed for flexible PU foam blocks, it covers low-density, high-resilience and slow-rebound foam production. Featuring stable mixing performance, wide density range and easy operation, it is widely used in furniture, bedding, packaging and automotive interior material factories.
Technical Document | June 2026 Haifeng Machinery
Basic Project Information
| Item | Detailed Specification |
|---|---|
| Raw Material System | PPG, POP, TDI, silicone oil, A33, T9, water, color paste and other additives (Manual dosing for minor ingredients) |
| Foam Density Range | 8 ~ 80 kg/m³ (Covers low-density, high-resilience & slow-rebound foam) |
| Mixing Mode | High-speed mixing, Max speed: 6000 rpm; Pneumatic tilting mixing barrel |
| Standard Mold Box | 2 sets, Dimension: L1050×W1050×H1200 mm |
| Casting Performance | Max single shot weight: approx 60 kg; Adjustable flow, Metering accuracy: ±0.5% |
| Control System | HMI + PLC semi-automatic control (Touch screen operation) |
| Standard Color | Industrial off-white & gray |
| Heating System | Internal coil heating for material tanks + Circulating water cooling & heating system |
Production Capacity Data
| Foam Type | Mold Size | Single Shot Weight | Single Cycle Time | 8h Shift Output | 16h Daily Output |
|---|---|---|---|---|---|
| Conventional Soft Foam (25kg/m³) | 1050×1050×1200 mm | Approx 33 kg | 25 ~ 30 mins | 16 ~ 18 blocks | 32 ~ 36 blocks |
| High-resilience Foam (45kg/m³) | 1050×1050×1200 mm | Approx 59 kg | 35 ~ 40 mins | 12 ~ 14 blocks | 24 ~ 28 blocks |
| Low-density Foam (12kg/m³) | 1050×1050×1200 mm | Approx 16 kg | 20 mins | 22 blocks | 44 blocks |
Remark: The actual output is 80% ~ 90% of the theoretical value, affected by formula, ambient temperature and operator proficiency. It is recommended to equip with slicing machines to improve overall efficiency.
Standard Production Process
| Procedure | Operation Description | Equipment | Picture |
|---|---|---|---|
| Raw Material Preheating | Heat PPG, POP, TDI to 20 ~ 40℃ via automatic constant temperature system; Weigh and prepare minor additives manually. | Raw Material Preheating Equipment |  |
| Mixing Preparation | Clean the mixing barrel, inspect pneumatic tilting device, transfer major materials into the barrel and add minor ingredients. | Mixing Barrel |  |
| High-speed Mixing & Casting | Start the mixing unit (Max 6000 rpm). After sufficient mixing, pour materials into the square mold box. | Mixing Head |  |
| Free Foaming | Materials expand and foam freely inside the mold box; Control reaction temperature with proper ventilation. | Square Mold Box |  |
| Demolding & Curing | Demold after 20 ~ 40 mins; Place foam blocks in curing area for more than 24 hours to achieve stable physical properties. | Curing Area |  |
| Cutting & Finishing | Use horizontal disc cutter and vertical cutter for slicing, trimming and final packaging. | Foam Cutting Machines |  |
Full Process Flow: Raw material tanks → High-speed mixing → Box foaming → Demolding & curing → Cutting → Finished product packaging
Full Equipment List
| Equipment Name | Model | Quantity | Overall Size (mm) | Core Parameters | Picture |
|---|---|---|---|---|---|
| Semi-automatic Box Foaming Machine | HF-SAF01 | 1 set | L3500×W2500×H2800 | Total power: 52 KW |  |
| Horizontal Disc Cutter | HF-HC02 | 1 set | W1500×L2000×H1200 | Blade length: 10000 mm, Power: 8.92 KW |  |
| Vertical Foam Cutter | HF-V03 | 1 set | 1720×2440 mm | Blade length: 8900 mm, Power: 1.74 KW |  |
| Square Mold Box | Custom | 2 sets | 1050×1050×H1200 | Aluminum / Steel structure | |
| Water Chiller | / | 1 set | / | Power: 1.91 KW, For temperature control |  |
| Air Compressor & Air Tank | / | 1 set | / | Power: 22 KW, Stable air supply |  |
| Automatic Feeding System | Optional | 1 set | / | Reduce manual operation | — |
| Raw Material Oven & Nitrogen Protection | Optional | 1 set | / | Anti-oxidation & preheating | — |
Core Component Specifications
Box Foaming Main Unit
- Mixing Barrel: Diameter 560 mm, Pneumatic tilting type, Mixing motor: 11 KW, Max speed: 6000 rpm
- Material Tanks: 3 sets (3T PPG / 3T POP / 3T TDI), Internal coil heating
- Temperature Control: Circulating water system, Adjustable range: 20 ~ 50℃, 1HP circulating pump
- Control System: Mitsubishi PLC + Delta 10-inch touch screen, French valves, Delta inverter
- Metering Pump: Domestic pump for PPG/POP, Shanghai pump for TDI; Metering accuracy ±0.5%
Horizontal Disc Cutter
Cutting thickness: 2 ~ 150 mm, Worktable speed: 0 ~ 3.5 rpm, Equipped with Japanese LINE encoder
Vertical Cutter
T75 lifting guide rail, Equipped with spare blade and grinding wheel
Workshop & Operating Requirements
| Item | Standard Requirement |
|---|---|
| Workshop Space | Hardened floor, Area ≥20m×10m, Independent raw material storage zone |
| Ambient Condition | Temp: 15 ~ 35℃, Humidity ≤80%, No condensation, Keep away from open fire |
| Power Supply | 3×380V ±5%, 50Hz, Reliable grounding, Total power: about 60 KW |
| Compressed Air | 0.6 ~ 0.8 MPa, Oil-free & dry, Air output ≥1.5 m³/min |
| Cooling Water | Temp ≤25℃, Flow ≥3 m³/h |
| Operators | 2 ~ 6 trained workers |
| Environmental Requirement | Equip local exhaust system, Comply with local VOC emission standards |
Power Consumption
- Total installed power: About 70 KW
- Actual operating power: 35 ~ 50 KW (Intermittent operation)
Common Defects & Troubleshooting
| Defect | Root Cause | Solutions |
|---|---|---|
| Uneven foam density | Unstable material temperature / Inaccurate metering | Calibrate pump; Stabilize raw material temperature |
| Foam shrinkage | Improper formula / Insufficient curing time | Adjust formula; Extend curing time |
| Internal voids & air holes | Poor ventilation / Raw material absorbs moisture | Enhance ventilation; Seal material tanks tightly |
| Hard & brittle foam | Excessive catalyst / Improper material ratio | Optimize additive dosage; Recheck formula |
| Slow foaming reaction | Low ambient temperature / Low material temperature | Increase preheating temperature |
Optional Upgrades & Customization
- Full automatic feeding system
- Nitrogen protection device for raw materials
- Custom-sized mold boxes
- Voltage & frequency adaptation for global power grids
- MES data tracking system
Packaging & Delivery
- Loading Capacity: 1 × 40GP container
- Package: EPE foam + Winding film, Export standard
- Production Lead Time: Within 30 working days after deposit
- Delivery Scope: Main unit, cutters, molds, standard spare parts
After-Sales Service
- Provide complete documents: Operation manual, electrical drawings, layout drawings and formula guide.
- Overseas engineer on-site installation, commissioning and operator training (Buyer bears relevant fees).
- Warranty period: 12 months from delivery date, free spare parts for non-artificial damage.
- Lifetime technical support and spare parts supply after warranty.
Frequently Asked Questions
Can this line produce different types of PU foam?
Yes, it supports low-density, high-resilience and slow-rebound foam by adjusting formulas.
Is the mold size customizable?
We can customize mold boxes of different dimensions according to your demands.
Can the equipment adapt to different national power?
We support voltage and frequency customization for global markets.
What is the key daily maintenance work?
Clean mixing barrel and pipelines daily; Check temperature and pressure per shift.
Can old lines be partially upgraded?
We provide targeted partial renovation solutions to save costs.
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