TDP-S-4 Low Noise Foam Crusher 1200-2000 kg/h 1200 mm Inlet Customizable Sieve Mesh

The TDP-S-4 is a low noise foam crusher built for high-capacity recycling of PU sponge and other soft scrap. It combines a 1200 mm wide inlet, a φ600×1200 mm rotor and a 75 kW drive to reach a crushing capacity of 1200–2000 kg/h, while an integrated sound insulation structure keeps operating noise below the level of a conventional open crusher. The sieve mesh can be specified in φ2, φ5, φ15 or φ30 mm, or customized to the particle size required by the end product.

This is a production-scale machine rather than a workshop unit. It is sized for rebonded foam factories, foam waste recycling plants, packaging material producers and rubber or plastic recyclers that process bulk scrap continuously. The wide inlet accepts larger pieces than a small crusher, and the heavy rotor maintains throughput when the feed is uneven. The machine weighs 5600 kg and measures 2500×2100×2900 mm.

The low noise design is a practical response to a common complaint about foam crushers. Crushing foam generates a high-frequency noise that carries through a workshop and becomes a labor and environmental issue. The TDP-S-4 uses a built-in sound insulation structure around the cutting chamber, so the machine can be installed closer to other equipment and operated for longer shifts without the noise becoming the limiting factor.

The TDP-S-4 is positioned between the small TDP-S-1/2 fine crusher and the heavy TDP-S-7/8 bale shredder. It can take pre-cut material directly, or accept the 50–100 mm output of a bale shredder and reduce it further. That makes it a flexible middle stage for plants that need high throughput without the very fine output of a dedicated fine grinder.

Foam recycling is a sequence of size reductions. Bales and large offcuts are opened and reduced to fragments; fragments are reduced to particles; particles are mixed with binder and pressed or used as filling. Each stage has an ideal infeed size, and a machine that is forced outside that range loses capacity or produces an inconsistent output.

The TDP-S-4 is designed for the middle of that sequence. Its 1200 mm inlet accepts pieces that would be too large for a small fine crusher, and its 75 kW rotor gives it the power to maintain 1200–2000 kg/h on a steady feed. With a coarse sieve it can act as a primary crusher for pre-cut offcuts; with a finer sieve it can produce material for the mixer or for filling. The same machine can therefore serve different roles depending on the sieve and the upstream process.

In a rebonded foam line, the TDP-S-4 is typically placed after a bale shredder and before the mixer. The shredder opens the bale, the TDP-S-4 reduces the fragments to a controlled particle size, and the mixer coats the particles with binder before the press forms the block. Matching the three stages keeps the line running at a steady rate and avoids the buffer piles that appear when one stage is oversized.

Foam crushing noise comes from two sources: the rotor and blades striking the material, and the material itself resonating as it breaks. An open chamber radiates that noise directly into the workshop. The TDP-S-4 surrounds the cutting chamber with a sound insulation structure, which absorbs and blocks a significant part of the high-frequency noise before it reaches the operator.

The practical benefits are straightforward. Operators can work without hearing protection for longer periods, the machine can be placed nearer to other stations, and the plant is less exposed to noise complaints from neighbouring areas. Noise is still present at the feed opening and discharge, so normal hearing protection should be worn near the machine, but the overall level is lower than an equivalent open crusher.

Sound insulation also has a maintenance dimension. The panels and seals around the chamber should be checked periodically, because a damaged panel or a worn seal lets noise escape and reduces the effectiveness of the design. This is a simple inspection item that is easy to overlook.

The machine is built on a heavy frame with a 1200 mm wide inlet and a horizontal rotor. At 5600 kg and 2500×2100×2900 mm, it is substantial enough to absorb the shock of uneven feeding without flexing.

• Rotor and blades — φ600×1200 mm rotor with replaceable cutting blades; the wide rotor gives the machine its throughput.
• Inlet — 1200 mm wide opening for pre-cut offcuts and shredded fragments.
• Sieve mesh — available in φ2, φ5, φ15 and φ30 mm, or customized; controls the maximum particle size.
• Sound insulation structure — encloses the cutting chamber to reduce radiated noise.
• Drive unit — 75 kW motor with overload protection for continuous recycling duty.
• Discharge section — delivers crushed material to a conveyor, bin or air conveying line.
• Safety guarding and interlocks — the inlet and drive are guarded, and the machine stops when a guard is opened.

• 1200–2000 kg/h capacity — production-scale throughput for rebonded foam and recycling plants.
• Low noise sound insulation — quieter operation than an open crusher of the same size.
• Customizable sieve mesh — φ2, φ5, φ15 or φ30 mm, or a custom size to match the end product.
• 1200 mm wide inlet — accepts larger pieces and reduces the amount of pre-cutting.
• 75 kW heavy-duty drive — maintains throughput on dense or unevenly fed material.
• Multi-material capability — PU sponge, EVA, PE, fabric, plastic and rubber scrap, subject to material testing.
• Rebond line compatibility — designed to work with a shredder, mixer and press as a complete system.

The sieve is the main control over output size. Material stays in the chamber until it is small enough to pass through the mesh, so a smaller mesh produces finer particles and a larger mesh produces coarser ones. The TDP-S-4 offers φ2, φ5, φ15 and φ30 mm as standard options, and custom sizes can be specified for a particular end product.

Mesh choice is a trade-off between particle size and throughput. A fine mesh keeps material in the chamber longer, which reduces capacity and increases wear; a coarse mesh passes material quickly, which raises output but gives a larger particle. For rebonded foam, a mix of sizes is often desirable; for filling, a finer particle may be preferred. The right choice depends on the end product, not on the machine alone.

Changing the sieve is a maintenance task rather than an operator adjustment. It should be done with the drive isolated, and the mesh should be checked for wear or deformation at the same time. A damaged mesh lets oversized pieces through and changes the particle distribution, so it should be replaced rather than repaired.

• PU sponge — the primary material; clean offcuts and shredded fragments.
• EVA — shoe, sports and tool-inlay scrap.
• PE foam — packaging and construction offcuts.
• Fabric and quilted foam — subject to testing, as fibre can wrap around the rotor.
• Plastic and rubber scrap — subject to hardness and thickness testing; not all grades are suitable.

The machine is designed for soft and semi-flexible scrap, with the multi-material capability stated for PU, EVA, PE, fabric, plastic and rubber. Hard or thick plastic and steel-reinforced rubber should be tested before a production order, because they load the rotor differently from foam. Mixed material containing metal, wood or stones should be sorted out before crushing.

Crushing waste PU sponge for bonded foam production. The 1200–2000 kg/h capacity matches the feed rate of a mid-size rebonding line.

Shredding EVA, PE and rubber scrap from collection and industrial sources into a conveyable, saleable material.

Recycling leftover foam and fabric trimmings from packaging production, reducing disposal cost and recovering material value.

Crushing waste plastic and rubber materials where the grade and thickness are within the machine's capability.

In a rebonded foam line, the TDP-S-4 normally sits between the bale shredder and the mixer. The shredder produces 50–100 mm fragments, the TDP-S-4 reduces them to the sieve size, and the mixer coats them with binder. The press then forms the rebonded block. The crusher is the stage that determines the particle distribution, and therefore the density and feel of the finished block.

Where the plant does not use a bale shredder, the TDP-S-4 can take pre-cut offcuts directly through its 1200 mm inlet. In that layout, the upstream cutting line must produce pieces small enough for the inlet, and the feed should be kept steady to avoid overload. We can review the complete line with the buyer and recommend the shredder, crusher and mixer combination before shipment.

The rated 1200–2000 kg/h assumes a steady feed of suitable material with a matching sieve. In practice, throughput depends on the feed rate, the material density, the sieve size and the condition of the blades. A continuous, moderate feed produces more output than dumping a large batch and waiting for the chamber to clear.

Discharge can be arranged to a conveyor, a bin or an air conveying line, depending on the plant layout. The discharge should be kept clear, because a blocked discharge backs material up into the chamber and reduces capacity. If the machine is connected to a mixer, a buffer hopper between the crusher and the mixer helps absorb short variations in feed rate.

• Versus TDP-S-1/2: the TDP-S-4 has roughly eight to ten times the capacity and a much wider inlet, but it is a larger investment and needs 75 kW rather than 15–30 kW. The small units suit workshops; the TDP-S-4 suits production lines.
• Versus TDP-S-7/8 bale shredder: the shredder is designed to open whole bales and produce 50–100 mm fragments; the TDP-S-4 is designed to reduce material to a controlled sieve size. They are complementary stages, not alternatives.
• Versus an open crusher: the sound insulation structure makes the TDP-S-4 quieter, which matters in a workshop with other equipment and in populated areas.

The inlet, rotor and 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 inlet by hand while the rotor is running; a pusher or conveyor should be used, and loose clothing and gloves should be kept away from the opening. The discharge and sieve should only be inspected with the drive isolated.

Operation is straightforward for a production machine. A new operator typically needs one to two days to learn the feed rate, recognise the sound of an overload and understand the shutdown and clearing procedure. The key skills are keeping an even feed, checking the sieve and blades, and monitoring the discharge. Training at installation, a printed operation manual and remote support are included.

• Foundation: a level, reinforced concrete floor able to carry 5600 kg plus dynamic load; anchor points are supplied.
• Power: a dedicated 75 kW supply with correct earthing, cable sizing and starting arrangement.
• Space: the 2500×2100×2900 mm footprint plus clearance for the inlet, discharge and sieve access.
• Daily checks: blade condition, sieve condition, sound insulation panels, guard interlocks and emergency stop.
• Weekly checks: bearing temperature, drive belt or coupling condition, bolt torque and lubrication points.
• Spares: rotor blades, sieve meshes, bearings, drive belts and insulation 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, reduces capacity and increases the load on the rotor. Sieve meshes wear or deform, which changes the particle size. Bearings and insulation seals should be checked regularly, because a failing bearing can damage the rotor and a damaged seal lets noise escape.

Each machine is assembled, wired and run before shipment. The test report covers rotor rotation, blade clearance, sieve fit, motor power, 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 because the 5600 kg weight affects the container and lifting plan. Delivery is 45 working days after downpayment, and payment terms are T/T or L/C.

The TDP-S-4 is the right choice when the plant needs 1200–2000 kg/h of crushed foam, a wide inlet and a quieter machine, and when the end product calls for a particle size that can be set by a sieve. It is not the right machine for whole bales without pre-shredding, for very fine powder, or for hard materials that have not been tested. Buyers should confirm the feed size and material, the required output, the target particle size, the available power and the site layout. Sharing those details lets us confirm the sieve, blade and discharge arrangement before the order.