TDP-S-7/8 Heavy Duty Sponge Shredding Machine 2000-3000 kg/h Foam Recycling Crusher

The TDP-S-7/8 is a heavy duty sponge shredding machine built for the first stage of a foam recycling line. It takes tightly baled PU sponge and waste foam blocks and reduces them to 50–100 mm fragments, which then go to a fine crusher, a mixer or a rebonding press. Two models cover different throughput requirements: the TDP-S-7 processes around 2000 kg/h with a 55 kW motor, and the TDP-S-8 reaches around 3000 kg/h with a 75 kW motor and a larger feed opening.

This is not a fine grinder. It is a coarse shredder, and that distinction matters in a recycling plant. A fine crusher works best when the infeed is already broken into pieces of a manageable size; feeding whole bales directly into a fine crusher causes bridging, overload and uneven output. The TDP-S-7/8 solves that by opening the bale and cutting it into fragments, giving the downstream equipment a consistent feed. That is why it is normally specified as the front-end machine of a rebonded foam line.

The shredding chamber is built around a heavy rotor with high-efficiency cutting blades and a robust frame. The TDP-S-7 weighs 8000 kg with a feed port of 1100×1250 mm and an overall size of 2900×2300×2800 mm; the TDP-S-8 weighs 10000 kg with a feed port of 1350×1400 mm and an overall size of 3200×2600×3000 mm. Both produce the same 50–100 mm fragment size, so the choice between them is a question of capacity and feeding logistics rather than output quality.

The machine is aimed at foam recycling plants, rebonded sponge producers, furniture and mattress factories that reuse their own scrap, and waste processors handling bulk foam. It can also be used to produce foam filling material directly, where the 50–100 mm fragment size is acceptable for the end product.

Waste PU foam arrives at a recycling plant in several forms: compressed bales from collection, offcuts from cutting lines, used mattress foam and rejected parts from furniture production. The material is light, springy and difficult to handle. A shredder turns it into a flowing, consistent fragment stream that can be conveyed, weighed, mixed and fed into the next process.

The TDP-S-7/8 performs that conversion in a single pass. Bales or large pieces are loaded into the feed port, the rotor pulls the material into the cutting chamber, and the blades reduce it to 50–100 mm pieces. The output falls through the discharge and is carried away by a conveyor or collected in a bin. Because the fragment size is controlled by the blade arrangement and the discharge opening, the downstream crusher receives a predictable feed instead of a mixture of bale chunks and dust.

The shredder also improves safety and housekeeping. Whole bales and large offcuts are awkward to move and store; once shredded, the material occupies a more regular volume and can be handled with standard conveying equipment. Dust and small debris are contained within the machine and discharge, rather than spreading across the floor.

The two models share the same working principle and output size. The difference is capacity and the physical size of the feed opening. The TDP-S-7 is rated at about 2000 kg/h with 55 kW and a 1100×1250 mm feed port. The TDP-S-8 is rated at about 3000 kg/h with 75 kW and a larger 1350×1400 mm feed port.

Capacity should be matched to the downstream line, not chosen in isolation. If the fine crusher and the mixing stage can only absorb 2000 kg/h, a TDP-S-8 will spend time idling or buffering, and the extra motor power buys nothing. If the downstream line can absorb 3000 kg/h and the baler produces large bales, the TDP-S-8 is the better choice because the larger feed opening reduces pre-cutting and the higher power keeps the chamber from bogging down on dense bales.

Site conditions matter too. The TDP-S-8 is 2000 kg heavier and roughly 300 mm larger in each dimension, so access, floor loading and conveyor layout should be checked before selection. Both machines produce 50–100 mm fragments, so the choice does not change the quality of the recycled material.

The shredder is built as a heavy welded frame around a horizontal rotor. The structure is deliberately massive: at 8000–10000 kg, the mass absorbs the shock of a partially opened bale and keeps the rotor speed stable when the load changes suddenly.

• Cutting rotor and blades — high-efficiency blade arrangement that grabs the foam and cuts it into 50–100 mm fragments rather than tearing it.
• Feed port — 1100×1250 mm on the TDP-S-7 and 1350×1400 mm on the TDP-S-8, sized for baled sponge and large offcuts.
• Drive unit — 55 kW on the TDP-S-7 and 75 kW on the TDP-S-8, with a heavy-duty transmission designed for start-stop loading.
• Discharge section — controls the fragment size and delivers the output to a conveyor or bin.
• Control panel — start/stop, emergency stop and overload protection; the drive is protected against jams caused by foreign objects.
• Safety guarding — the feed opening and drive are guarded, and the machine stops when the guard is opened.

• Built for baled sponge — the heavy rotor and high torque open compressed bales that would stall a lighter machine.
• Two capacity options — 2000 kg/h and 3000 kg/h, so the shredder can be matched to the downstream line instead of being oversized or undersized.
• Consistent 50–100 mm output — gives the fine crusher and mixer a predictable feed and avoids bridging.
• Heavy duty structure — 8000–10000 kg frame and a robust drive train for continuous recycling duty.
• Low noise operation — the enclosed cutting chamber and heavy frame reduce noise compared with open granulators.
• Front-end of a rebonded foam line — designed to work with a fine crusher, mixer and rebonding press as a complete system.
• Versatile output — fragments can go to rebonded foam production or be used directly as filling material.

The rotor turns at speed inside a fixed cutting chamber. Blades on the rotor work against the chamber geometry to grip the foam, compress it against the cutting edge and separate it into pieces. Because foam is elastic, the machine cannot rely on gravity alone; the feed opening and rotor design pull the material in and keep it moving instead of letting it bounce on the surface.

The 50–100 mm output range is a deliberate compromise. Smaller fragments would need more energy and a finer screen, and the material would start to behave like dust, which is harder to convey and mix. Larger fragments would be slow to break down in the fine crusher and could cause bridging in the mixer. The 50–100 mm range feeds well, mixes well and keeps the downstream process stable.

Output size is affected by blade condition, rotor speed and the discharge arrangement. Worn blades produce longer, stringy pieces and reduce capacity, so blade inspection is part of routine maintenance. Foreign objects such as metal, wood or hard plastic should be removed from the infeed before shredding, because they can damage the blades and the rotor.

• Baled PU sponge — the primary infeed; compressed collection bales are opened and shredded in one pass.
• Flexible PU foam offcuts — trimmings from furniture, mattress and packaging production.
• Used mattress and cushion foam — where the material is clean enough for recycling.
• Rebond scrap — rejected pieces from rebonded foam production, returned to the front of the line.
• Other soft foam waste — PE and EPE offcuts, subject to a material check before processing.

The shredder is intended for soft and flexible foam. It is not designed for rigid foam, foam with hard inclusions, metal, wood or wet material. Contaminated foam should be sorted before it reaches the shredder, because the cost of blade damage and downtime is much higher than the cost of sorting.

Pre-shredding of baled PU sponge before fine crushing. This is the most common application: the shredder opens the bale and produces fragments that the fine crusher can handle efficiently.

Processing bulk waste foam scraps from collection and industrial sources into a conveyable, storable material.

Recycling in-house offcuts into foam filling material, reducing waste disposal cost and recovering value from production scrap.

Supporting equipment for a complete recycling line, feeding the crusher, mixer and rebonding press in a controlled sequence.

The TDP-S-7/8 is the first machine in a foam recycling line. Upstream, it receives baled or bulk waste foam. Downstream, its output goes to a fine crusher, then to a mixer where adhesive is added, then to a rebonding press or a filling line. The shredder sets the pace for the whole line: if it produces fragments that are too large or too uneven, the crusher and mixer will run below capacity.

In a typical layout, the shredder is fed by conveyor or by a forklift with a hopper. The discharge conveyor carries fragments to the fine crusher, and a metal detector or a manual inspection point is placed between the shredder and the crusher to catch foreign objects. We can review the complete line with the buyer and recommend the shredder model, conveyor arrangement and buffer capacity before shipment.

Rated capacity is measured on a steady feed of typical baled PU sponge. In practice, throughput depends on how evenly the machine is fed: a continuous, moderate feed produces more output than dumping a whole bale and waiting for the chamber to clear. The feed port on the TDP-S-8 is larger, which allows bigger pieces and reduces the time spent pre-cutting bales.

Feeding logistics should be planned together with capacity. A 3000 kg/h shredder needs a baler or collection system that can deliver material at that rate, plus enough buffer storage to keep the line running during changes. If the plant cannot supply 3000 kg/h consistently, the TDP-S-7 is usually the more economical choice, because it runs closer to its design point instead of idling.

The feed opening is the main hazard area, and it is guarded so that the operator cannot reach the rotor. The drive and discharge are also guarded, and the machine stops when a guard is opened. Emergency stops are placed at the operator position. Material should never be pushed into the chamber by hand; a proper pusher or conveyor feed should be used, and loose clothing and gloves should be kept away from the feed opening.

Operation is straightforward. A new operator typically needs one to two days to learn the feed rate, recognise the sound of a jam, and understand the shutdown and clearing procedure. The key skills are keeping an even feed, removing foreign objects before they enter, and checking the output size. Training at installation, a printed operation manual and remote support are included.

• Foundation: a level, reinforced concrete floor able to carry the machine weight plus dynamic load; anchor points are supplied.
• Power: a dedicated supply matching the 55 kW or 75 kW motor, with correct earthing, cable sizing and starting arrangement.
• Space: clearance for the feed opening, discharge conveyor and blade access; the TDP-S-8 needs a larger area than the TDP-S-7.
• Daily checks: blade condition, rotor freedom, guard interlocks and emergency stop.
• Weekly checks: drive belt or coupling condition, bearing temperature, lubrication points and bolt torque.
• Spares: rotor blades, counter blades, bearings, drive belts and screens are the usual consumables; we keep these available for repeat buyers.

Blades wear on the cutting edge and at the corners. A dull blade produces longer pieces and reduces capacity, and it increases the load on the rotor. Blades can usually be re-sharpened several times before replacement. Bearing condition should be checked regularly, because a failing bearing can damage the rotor and turn a routine maintenance item into a major repair.

Each machine is assembled, wired and run before shipment. The test report covers rotor rotation, blade clearance, drive power, overload protection, guard interlocks, emergency stop and a sample shred measured for fragment size. The buyer receives the inspection record with the machine.

The machine is shipped in export-grade packaging with the frame protected against moisture, the rotor secured, and loose parts boxed and labelled. Packaging details are confirmed with the buyer before dispatch because the TDP-S-8 dimensions and weight affect the container plan. Delivery is 45 working days after downpayment, and payment terms are T/T or L/C.

The TDP-S-7/8 is the right choice when the infeed is baled or bulky soft PU foam and the output is destined for fine crushing, mixing or filling. It is not the right machine for rigid foam, contaminated material or fine grinding; a different crusher is needed for the final particle size. Buyers should confirm the infeed form and bale size, the required output per hour, the downstream crusher capacity, the available power and the site layout. Sharing those details lets us confirm the model, feed arrangement and spare blade requirement before the order.