TDP-S-1/2 Foam Shredding Machine 2-30 mm Crushing Particle 150-300 kg/h 15-30 kW

The TDP-S-1/2 is a compact foam shredding machine built for fine crushing of PU foam offcuts and scrap. It reduces foam waste to a 2–30 mm particle size — the range used for rebonded sponge production and for foam filling in cushions, pillows and mattresses. Two models are available: the TDP-S-1 at about 150 kg/h with a 15 kW motor, and the TDP-S-2 at about 300 kg/h with a 30 kW motor.

This is a fine crusher, not a bale shredder. It is designed to take material that has already been reduced to manageable pieces and bring it down to a consistent particle size. In a recycling line it usually sits after a coarse shredder: the shredder opens bales and cuts them to 50–100 mm fragments, and the TDP-S-1/2 crushes those fragments to 2–30 mm. For a small workshop that buys clean offcuts rather than whole bales, the machine can also be used on its own.

The unit is deliberately compact. The TDP-S-1 weighs 700 kg and measures 1500×500×800 mm; the TDP-S-2 weighs 1000 kg and measures 1800×600×1000 mm. That makes it suitable for workshops with limited floor space and for plants that want to add a fine crushing step without rebuilding the production area. A powerful air blower conveys the crushed material out of the machine, which simplifies discharge and reduces manual handling.

The machine is aimed at small foam recycling workshops, furniture and bedding factories that reuse their own offcuts, packaging foam converters, and larger recycling plants that need a fine crushing stage after a coarse shredder. It is an entry-level unit in terms of investment, but it uses the same blade-and-screen principle as larger crushers, so the output is consistent rather than random.

The distinction between a shredder and a crusher is important when specifying a recycling line. A shredder produces large fragments — typically 50–100 mm — and its job is to break open bales and reduce bulk so the material can be conveyed and fed. A crusher produces small particles — in this case 2–30 mm — and its job is to create a consistent material for mixing, bonding or filling.

Putting whole bales into a fine crusher is counterproductive: the chamber bridges, the rotor slows, and the particle size becomes uneven. Putting already-small offcuts into a coarse shredder wastes capacity and produces a material that is still too large for the next step. The TDP-S-1/2 is positioned firmly on the fine side of that division, and the recommended feed is material that has already been cut to a manageable size.

The 2–30 mm range is wide because different end products need different particles. Rebonded foam usually wants a mix of sizes so the binder can coat the surfaces and the pressed block has good density. Filling material for cushions and pillows may want a smaller, softer particle. The machine’s screen arrangement determines the upper limit, while the blade condition and feed rate affect how consistently the lower end is reached.

The two models share the same 2–30 mm output and the same working principle. The difference is capacity, motor power and physical size. The TDP-S-1 is rated at about 150 kg/h, uses a 15 kW motor, weighs 700 kg and measures 1500×500×800 mm. The TDP-S-2 is rated at about 300 kg/h, uses a 30 kW motor, weighs 1000 kg and measures 1800×600×1000 mm.

Capacity should be matched to the actual supply of material. A small furniture factory that generates a few hundred kilograms of offcuts per day will rarely keep a 300 kg/h machine busy, and the TDP-S-1 will run closer to its design point. A workshop that buys baled or bulk scrap and runs a full shift is better served by the TDP-S-2, because the extra capacity absorbs peaks and reduces the risk of a backlog.

Power supply is the other deciding factor. The TDP-S-1 needs a 15 kW supply and the TDP-S-2 needs 30 kW. In a small workshop with a limited electrical service, that difference can decide the model. Both machines run on the same principle and produce the same particle range, so the choice is about throughput and site conditions, not output quality.

The machine is built as a compact steel housing around a crushing rotor, with a screen that controls the particle size and an air blower for discharge. The small footprint is achieved by mounting the drive and the blower close to the chamber, so the unit can be placed in a corner of an existing workshop.

• Crushing rotor and blades — high-speed rotor with cutting blades that reduce foam offcuts to 2–30 mm particles.
• Screen — retains oversized material until it is small enough to pass, which is what keeps the output consistent.
• Air conveying blower — discharges the crushed particles through a pipe or duct, reducing manual handling and dust accumulation.
• Drive unit — 15 kW on the TDP-S-1 and 30 kW on the TDP-S-2, with overload protection.
• Feed hopper — sized for manual or conveyor feeding of pre-cut offcuts.
• Safety guarding and interlocks — the feed opening and drive are guarded, and the machine stops when a guard is opened.

• Fine 2–30 mm particle output — suitable for rebonded foam and for cushion, pillow and mattress filling.
• Two compact models — 150 kg/h and 300 kg/h, so a small workshop can match the machine to its actual scrap volume.
• Low investment, small footprint — 1500×500×800 mm for the TDP-S-1 and 1800×600×1000 mm for the TDP-S-2.
• Air conveying discharge — a strong blower moves the crushed material out of the machine and into a collection bag or bin.
• Consistent particle size — the screen controls the upper limit, so the output does not vary from batch to batch.
• Simple operation — one operator can feed, bag and monitor the machine; no specialised skills are required.
• Entry point to foam recycling — an economical way for a small factory to turn offcuts into reusable material instead of paying for disposal.

The 2–30 mm output is a range, not a single number. In practice, the crushed material contains a mixture of particle sizes within that band, and the proportion depends on the screen, the blade condition, the rotor speed and how evenly the machine is fed. A screen with smaller openings shifts the distribution toward the lower end; a worn blade produces more elongated pieces and fewer clean particles.

For rebonded foam, a mixed particle size is usually desirable because the binder needs surface area to form strong bonds between particles, and a mix packs into a denser block. For filling applications, a finer, softer particle is often preferred. Buyers should tell us the end use so we can recommend the screen and blade setup rather than leaving the particle size to chance.

Particle size is also affected by the feed material. Clean, dry PU offcuts crush consistently. Foam with fabric, adhesive or film attached will not break down in the same way, and the foreign material may wrap around the rotor. Sorting the infeed is therefore part of achieving a consistent output.

The TDP-S-1/2 uses a powerful air blower to move crushed particles out of the machine. The material exits through a duct and can be directed into a collection bag, a bin or a cyclone. This is a practical advantage in a small workshop: the machine does not need to sit directly over a collection container, and the operator does not have to shovel material out of the discharge.

Air conveying also helps with dust control. Foam dust is light and spreads easily, and a closed discharge duct keeps most of it inside the system. The collection point should still be checked regularly, and the bag or bin should be changed before it is full so the duct does not back up. If the airflow drops, the first things to check are the duct for blockages and the collection bag for overfilling.

• PU foam offcuts — the primary feed; clean trimmings from furniture, mattress and packaging production.
• Flexible foam scrap — rejected parts and cut-offs from converting lines.
• PE and EPE offcuts — subject to a material check, as harder foams crush differently from soft PU.
• Clean, dry foam — moisture and contamination reduce output and accelerate blade wear.

Crushing PU foam trimmings into particles that can be mixed with binder and pressed into reconstituted foam. This is the most common use of the machine.

Recycling leftover offcuts from cutting and converting processes instead of paying for disposal, turning a waste stream into a usable raw material.

Producing foam filling particles for cushions, pillows and mattress pads, where a soft, consistent particle improves the feel of the finished product.

An entry-level crushing unit for workshops that want to start foam recycling without a large capital investment or a large floor area.

The TDP-S-1/2 sits in the middle of a foam recycling line. Upstream, it receives pre-cut offcuts or the output of a coarse shredder. Downstream, its particles go to a mixer where binder is added, then to a rebonding press, or directly to a filling and bagging station. In a small workshop it may be the only machine in the line, with manual feeding and bagging.

Where a coarse shredder is used, the sequence is: bale shredder → fine crusher → mixer → press. The shredder’s 50–100 mm output is a good feed for the TDP-S-1/2, and the crusher’s 2–30 mm output is a good feed for the mixer. Matching the capacities of the three stages avoids buffering and keeps the line running at a steady rate. We can review the complete process with the buyer and recommend the model and conveyor arrangement before shipment.

The rated capacity of 150 kg/h or 300 kg/h assumes a steady feed of clean, pre-cut foam. In a small workshop the actual average is usually lower, because feeding is manual and the operator also handles bagging and inspection. Even so, a TDP-S-1 running a few hours a day can process a meaningful volume of offcuts that would otherwise be discarded.

The economics are simple: the machine converts a waste disposal cost into a reusable material. For a furniture or mattress factory, the crushed foam can be used in its own filling products or sold to a rebonding plant. For a small recycling workshop, the machine is the entry point that makes it possible to buy clean offcuts and sell crushed material without investing in a full production line. The compact size and 15 kW supply requirement keep the installation cost low.

The feed opening and the drive are guarded, and the machine stops when a guard is opened. Emergency stop is placed at the operator position. Material should never be pushed into the hopper by hand while the rotor is running; a pusher should be used, and loose clothing and gloves should be kept away from the opening. The air discharge duct should be checked for blockages only after the machine has stopped.

Operation is simple. A new operator typically needs a few hours to learn the feed rate, recognise a blocked screen and change a collection bag. The main skills are feeding evenly, keeping the material clean and checking the particle size at the start of each batch. Training at installation, a printed operation manual and remote support are included.

• Foundation: a level concrete floor able to carry 700–1000 kg; the machine can be bolted down if vibration is a concern.
• Power: a dedicated supply matching the 15 kW or 30 kW motor, with correct earthing and cable sizing.
• Space: clearance around the feed hopper, the discharge duct and the collection point.
• Daily checks: blade condition, screen condition, air duct and collection bag, guard interlocks and emergency stop.
• Weekly checks: bearing temperature, drive belt tension, bolt torque and lubrication points.
• Spares: rotor blades, screens, bearings, drive belts and air duct seals are the usual consumables; we keep these available for repeat buyers.

Blades wear at the cutting edge, and a dull blade produces longer pieces and reduces capacity. Screens wear or deform over time, which changes the particle size; a damaged screen should be replaced rather than repaired. Bearings 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, screen fit, air conveying performance, overload protection, guard interlocks, emergency stop and a sample crush measured for particle 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. Delivery is 45 working days after downpayment, and payment terms are T/T or L/C.

The TDP-S-1/2 is the right choice when the feed is clean, pre-cut flexible foam and the required output is 2–30 mm particles for rebonding or filling. It is not the right machine for whole bales, rigid foam or contaminated material; a coarse shredder or a different crusher is needed for those. Buyers should confirm the feed size, the required output per hour, the end use of the particles, the available power and the floor space. Sharing those details lets us confirm the model, screen and blade setup before the order.