TDP-4LS Vertical Cutting Machine Raises Insole Foam Accuracy for Pakistan Footwear Factory

In 2025 a footwear component manufacturer in Sialkot, Pakistan, producing EVA and PU foam insoles for local brands and export orders, replaced hand-guided cutting with a TDP-4LS automatic vertical cutting machine. Within three months of commissioning the factory had stabilised sheet thickness, reduced foam scrap and moved from four skilled cutters to two operators per shift.

The factory was cutting EVA and PU foam buns into thin insole sheets with a hand-fed vertical cutter. The process depended almost entirely on operator skill, and the problems had become a bottleneck for export orders:

• Thickness variation: sheets drifted between 2 mm and 4 mm across a single bun, so die-cut insoles often needed manual sanding to match spec.
• High foam scrap: inconsistent slices were rejected at the assembly stage, pushing material waste above acceptable levels on every batch.
• Skilled labour dependency: four experienced cutters were needed per shift, and output dropped sharply when one was absent.
• Slow changeover: switching between 3 mm, 5 mm and 8 mm insole gauges required re-setting by trial cuts, costing 20-30 minutes each time.
• Blade drift and downtime: the old machine drifted under load, and blade changes were frequent and time consuming.
• Delivery pressure: rising orders from local brands and Middle East buyers could not be met with the existing cutting capacity.

After reviewing the cutting height, table size and thickness range required for insole production, we recommended and supplied the TDP-4LS automatic vertical cutting machine. The configuration matched the factory's actual bun size, so no oversize table was needed and floor space stayed within the existing cutting room.

• 1250 mm cutting height: full foam buns are loaded in one pass instead of being split into shorter blocks first.
• Digital size setting: thickness is entered on the control panel, removing trial-and-error re-setting between insole gauges.
• 1320 x 2500 mm inner table / 1800 x 2500 mm outer table: supports long EVA sheets and standard PU buns used for insole stock.
• 8000 mm band blade: longer blade length means lower blade temperature and less drift during continuous cutting.
• 1.68 kW drive: low power draw, which matters for a factory running the cutter through two shifts.
• Rigid 1800 kg frame: reduces vibration so sheet edges stay square even at maximum bun height.

Installation and commissioning took five working days, including foundation levelling, electrical connection, blade tracking adjustment and operator training on thickness setting and blade tensioning. Two operators and one maintenance technician were trained on daily checks, blade replacement and the safety guard sequence.

The factory now runs the TDP-4LS across two shifts and has taken on additional insole orders from Middle East buyers without adding cutting staff. Because thickness is set digitally, new operators reach production quality within days rather than months.

• Matching cutting height and table size to the real bun dimensions instead of buying an oversized machine.
• Digital thickness setting removing the trial cuts that used to consume both time and foam.
• Keeping spare blades and guides on site to avoid import delays.
• Training maintenance staff on blade tracking, which protects cut quality between service visits.

Factories running this configuration often pair the vertical cutter with a foam laminating machine for bonding fabric to insole sheet, and a die-cutting press for final insole shapes.

"Thickness is now something we set, not something we hope for. Our sanding station is almost idle and we ship the same insole gauge every time." – Production manager, insole division

If your factory cuts EVA, PU or EPE foam for insoles, footwear lining or mats, contact our team with your bun size, target thickness range and daily output so we can confirm whether the TDP-4LS or an oversize model fits your line.