3 Blocks per Hour Rebonded Foam Machine with 2100x1800x1000 mm Mould for Waste Sponge Recycling

TDP-10 Rebonded Foam Making Line 2100x1800x1000 mm Mould 3 Blocks per Hour for Waste Sponge

Product Introduction

The TDP-10 rebonded foam making line converts crushed PU sponge scrap into dense, uniform rebonded foam blocks. Waste foam is shredded, blended with binder in a 15 m³ stirring chamber, pressed into a 2100 x 1800 x 1000 mm mould and cured either by steam or by natural air drying. Each cycle produces a block that can be cut, laminated or profiled into mats, underlay and cushioning products — meaning scrap that used to be sold by weight can be reprocessed into finished material with a much higher margin.

The line runs at 3 blocks per hour with a 33 kW drive package and a total machine weight of 8000 kg. Because both steam curing and natural drying are supported, the same line can be installed in workshops with an existing boiler or in plants that prefer a low-energy air-dry process.

1. Shredding: Waste PU sponge, trim scrap and off-cuts are reduced to a controlled chip size by a sponge shredder or foam crusher.
2. Binder mixing: Chips enter the 15 m³ stirring chamber running at 40 r/min, where binder is sprayed and distributed evenly.
3. Mould filling: The mixed material is loaded into the 2100 x 1800 x 1000 mm mould and pressed to the target density.
4. Curing: Steam is injected for fast curing, or the filled mould is left for natural air drying where steam is not available.
5. Demoulding and cutting: Cured blocks are demoulded and then peeled, split or profile-cut on a vertical or horizontal foam cutting machine.

• Waste sponge recycling with real payback — scrap foam becomes rebonded block stock instead of landfill or low-value baling.
• 15 m³ stirring volume at 40 r/min — large batch capacity with even binder distribution for consistent block density.
• 3 blocks per hour output — the 2100 x 1800 x 1000 mm mould size gives predictable daily volume for planning.
• Steam or natural air curing — choose fast steam cycles or low-energy air drying depending on your workshop.
• 33 kW installed power, 8000 kg frame — a robust welded structure that holds mould alignment under repeated pressing cycles.
• Full automatic control — one operator manages the stirring, filling and curing sequence from the control panel.

The TDP-10 is normally the centre of a small recycling plant. Depending on how much automation you need, it can be paired with:

• Foam shredder / sponge crusher — prepares scrap into uniform chips before mixing; output size directly affects binder consumption and block strength.
• Binder mixing and spraying unit — meters the adhesive ratio; typical binder content is adjusted by target density and chip size.
• Steam boiler or hot air generator — only required for the steam curing option; natural drying needs no boiler but takes longer per batch.
• Vertical or horizontal foam cutting machine — splits cured blocks into sheets, mats and profiled parts; a band knife slitter handles blocks up to full mould height.
• Foam laminating machine — bonds fabric, film or non-woven to rebonded sheet for gym flooring, mats and upholstery.
• Foam baler — compacts leftover trim and dust for storage or resale.

The line processes crushed flexible PU foam, memory foam scrap, mattress trim, packaging foam off-cuts and mixed sponge waste. Rebonded block density is controlled by press ratio and binder content rather than by the input foam alone, so the same scrap stream can be run to different densities for different end products — lighter blocks for cushioning and underlay, denser blocks for gym mats, carpet backing and load-bearing padding.

• Sports and fitness: gym mats, exercise flooring, fitness equipment padding and martial arts mats.
• Livestock: anti-slip cow mats and barn flooring for dairy farms.
• Furniture and bedding: cushion cores, sofa padding and mattress support layers.
• Footwear: base foam for shoe soles and insoles.
• Automotive and transport: shock-absorbing padding for interiors and cargo protection.
• Construction and decoration: acoustic panels, underlay and floor mats.

• Volume planning: at 3 blocks per hour, a single shift yields roughly 24 blocks; confirm mould height and target density against your cutting capacity.
• Curing choice: steam curing shortens cycle time and raises daily output; natural drying lowers energy cost but needs floor space for moulds to stand.
• Power and space: plan 33 kW for the line itself plus the shredder and boiler loads, and reserve about 4000 x 4000 x 5400 mm for the machine, with additional space for moulds and block storage.
• Cutting match: check that your existing cutting machine can handle the full 2100 x 1800 x 1000 mm block, otherwise specify an oversize table.

The line ships with foundation and layout drawings, wiring diagrams and an operation manual. Installation typically takes a few days with local rigging, followed by commissioning support for mixing ratio, cycle timing and first block quality.

Routine maintenance covers stirring shaft and blade inspection, mould guide lubrication, steam line and valve checks, and control panel cleaning. Wear parts such as mixing blades, seals and mould liners are stocked for fast replacement so a single worn component does not idle the line.

Each unit is run and inspected before shipment, with CE electrical configuration available for European and other export markets. The main frame is shipped in containers with rust-proof treatment, while the control cabinet, motors and small components are packed in wooden cases. Standard delivery is about 45 working days after downpayment, and packing details are confirmed against the final configuration.