TDB-01 7.5kW Waste Sponge Vertical Baler 800mm Stroke 900x700x1000mm Bale for Foam Recycling

The TDB-01 waste sponge vertical baler compresses large foam blocks into compact bales before storage and transport.

Product Introduction

TDB-01 vertical baler is specially designed for foam and sponge compression. It compresses bulky foam blocks to shrink volume greatly, which saves logistics cost and facilitates storage and shipment.

It handles foam up to 900×700×1000mm with an 800mm maximum stroke and a 7.5kW motor, and its vertical hydraulic structure keeps the footprint small enough for a foam processing workshop. Used as supporting equipment in foam recycling and rebonded foam lines, it cuts storage space and freight cost by reducing the volume of bulky waste before the material moves to the next process.

Waste foam is bulky and light. A truck filled with loose sponge offcuts carries very little actual material, and a warehouse filled with loose blocks runs out of space long before it runs out of weight capacity. Baling solves both problems: the foam is compressed into a dense, stable bale that stacks neatly, loads efficiently and can be handled by a forklift without falling apart.

The TDB-01 is a vertical baler. The foam block is loaded into the compression chamber, a hydraulic ram moves down through an 800mm stroke, and the compressed mass is then packed for transport. Vertical design means the machine grows upward rather than outward, which matters in workshops where floor space is already taken by shredders, mixers and cutting machines.

The baler does not change the material itself. It does not shred, mix or bond foam. Its job is purely mechanical: reduce volume, stabilise the block and make the material economical to move. That is why it is normally placed either before transport, when scrap leaves the factory, or before shredding, when the recycling line needs a steady, compact feed of material.

A rebond foam line typically runs in this order: collection of waste foam, baling or storage, shredding and grinding, mixing with binder, foaming into blocks, curing, then cutting into sheets. The baler sits near the front of that chain.

Before transport. Factories that collect foam from several sources can bale the material at the collection point, then ship compact bales to the recycling plant. Freight is charged by volume in practice, so compression directly reduces the cost per tonne of material moved.

Before shredding. A shredder works best when it is fed at a steady rate. Bales can be opened and fed in controlled amounts, which avoids the surge that happens when loose trimmings are dumped into the hopper. The result is a more stable load on the shredder motor and a more consistent granule size.

As buffer storage. Baled foam takes far less floor space than loose foam, so a plant can build a buffer between collection and processing. This is useful when waste arrives in large batches but the line runs at a constant rate.

The TDB-01 uses a vertical hydraulic press. The 7.5kW motor drives the hydraulic system, and the ram travels up to 800mm to compress the foam against the base of the chamber. The working envelope accepts foam blocks up to 900×700×1000mm, which covers the common block sizes produced by foam cutting and foaming operations.

Compression is a density operation, not a cutting operation. The foam cells collapse under pressure, air is expelled, and the block retains its compressed shape long enough to be packed and strapped. Because the material is elastic, the compression ratio that can be reached depends on the foam type, the block size and how the bale is restrained after pressing. PU sponge compresses readily; denser EVA and rubber-containing scrap resist compression and need more attention during packing.

• Load evenly. Distribute foam across the chamber instead of piling it in one corner, so the ram applies force uniformly.
• Respect the chamber size. Oversized blocks should be reduced before loading. Forcing material above the rated 900×700×1000mm envelope distorts the bale and strains the frame.
• Pack immediately. Strap or wrap the bale as soon as the ram is released, before the foam springs back.

The TDB-01 is built as a self-supporting vertical press with a small floor footprint.

Frame and compression chamber. The frame carries the reaction force of the hydraulic ram and keeps the chamber aligned through the full 800mm stroke. The chamber is sized for the rated maximum foam block of 900×700×1000mm.

Hydraulic power unit. A 7.5kW motor drives the pump that pressurises the cylinder. The power unit is matched to the chamber size so that the ram moves steadily through the stroke rather than in surges.

Ram and guide system. The ram is guided through the stroke to keep the pressing face level. A level face is what produces a rectangular bale instead of a wedge-shaped one.

Controls and safety. The control station groups the press, hold and return functions. Guards and interlocks keep the operator outside the compression zone while the ram is moving. The machine weighs 2500kg and measures 1300×1120×3000mm, so it can be placed in a workshop corner and does not require a large foundation.

The TDB-01 is designed for PU sponge and foam blocks, and it is used across foam recycling and rebonded foam production. Typical input includes block offcuts, rejected foam blocks, mattress and furniture trimmings, and foam collected from cutting lines.

Loading practice matters more than most buyers expect. Foam is light, so it is tempting to overfill the chamber and rely on the ram to force everything down. That is the fastest way to produce a bale that splits open later. A better routine is:

• Fill the chamber in layers and keep the load level.
• Keep hard foreign objects out: metal clips, wood, stones and hard plastic can damage the ram face and puncture the bale.
• Keep the material dry. Wet foam compresses differently and can grow mould in storage.
• Separate foam types when the bales are intended for a specific recycling recipe, because a mixed bale is harder to dose accurately at the shredder.

• Volume reduction: hydraulic compression shrinks large foam blocks to save storage and freight cost.
• Specially for foam: designed for PU sponge and foam blocks, matching rebonded foam production requirements.
• Simple operation: vertical hydraulic structure, stable and easy to operate.
• Compact footprint: 1300×1120×3000mm overall dimension fits foam processing workshops.
• Matched working envelope: accepts blocks up to 900×700×1000mm with an 800mm stroke.
• Global support: remote technical assistance, spare parts supply and installation guidance.

Bale density and compression ratio depend on foam type, block size and packing method. The rated figures describe the machine envelope, not the finished bale weight.

A bale is only useful if it stays together during handling and transport. Three factors decide that: how evenly the chamber was loaded, how long the ram is held at pressure, and how quickly the bale is restrained after release.

Hold time. Give the ram time to work. Foam is viscoelastic, so the material continues to collapse while pressure is held. Releasing early leaves internal stress that makes the bale expand as soon as the straps are tensioned.

Restraint. Strapping, wrapping or bagging must be applied while the bale is still compressed. The packing method should match the transport mode: a bale that travels by container needs more restraint than one that moves a few metres to the shredder.

Stacking. Store bales on a level floor and avoid stacking them higher than the packing method allows. A bale that leans will slowly deform, and a deformed bale is harder to feed into the shredder.

• Rebonded foam factory: compress waste sponge before shredding and recycling.
• Foam processing plant: dense packing of foam blocks for shipment.
• Waste foam recycling: reduce the volume of bulky foam scraps at collection points.
• Mattress and furniture factory: compress leftover PU sponge trimmings and rejected blocks.
• Cutting and foaming workshops: turn daily offcuts into stackable units instead of loose piles.
• Warehouse and transfer stations: build buffer stock in a fraction of the floor space.

The economics of foam waste are dominated by volume. A container or truck fills up long before it reaches its weight limit, so the cost per tonne of material is really a cost per cubic metre. Compression attacks that cost directly.

There are three separate savings:

1. Freight: fewer trips for the same tonnage, and lower cost per tonne when waste is moved between sites.
2. Storage: bales stack, loose foam does not. A plant can hold more material in the same floor area, which improves bargaining position when selling scrap or buying waste.
3. Handling: bales can be moved with a forklift or pallet truck in one movement, while loose foam needs repeated manual handling.

For factories that ship recycled foam products, baled input also stabilises production planning: the material is pre-compacted, easy to count and easy to store under cover.

Buyers often compare vertical and horizontal balers. The right choice depends on volume and space rather than on price alone.

• Floor space: a vertical baler such as the TDB-01 occupies 1300×1120mm of floor and grows to 3000mm in height, which suits workshops with limited area.
• Throughput: horizontal balers are usually chosen for continuous, high-volume baling; a vertical baler is well matched to batch operation alongside a recycling line.
• Loading: vertical machines are loaded from the front or top by hand or with a small conveyor, which is practical for offcuts and block pieces.
• Manual compaction: compressing foam by hand or with simple weights cannot reach the density of a hydraulic press, and the resulting bales are unstable in transport.

For a rebond line that processes a few blocks per hour, the TDB-01 provides hydraulic compression without the floor area and capital cost of a horizontal baler.

Installation is straightforward, but a few checks prevent later problems.

• Floor: a level, load-bearing concrete floor. The machine weighs 2500kg, and the pressing force passes through the base, so the floor must be sound.
• Height: the machine is 3000mm tall. Allow clearance above it for loading and for maintenance access to the hydraulic unit.
• Power: a supply sized for the 7.5kW motor with correct protection. Confirm local voltage and frequency before the order is fixed.
• Access: space in front of the chamber for loading and removing bales, and space at the side for the hydraulic power unit.
• Environment: keep the machine under cover and away from excessive dust and water. Foam dust should be cleaned regularly.

Commissioning includes a dry run, a test press with representative foam, adjustment of the stroke limit and operator training on loading and packing.

The TDB-01 is simple to operate, but the compression zone is a hazard and must be treated as one.

• Before pressing: confirm the chamber is loaded evenly, the guards are closed and no one is standing in the compression area.
• During pressing: never reach into the chamber. Use the hold function when positioning packing material.
• After pressing: restrain the bale before releasing the ram, then remove it with the approved handling method.
• Lockout: isolate power before cleaning, servicing the hydraulic system or replacing components.
• PPE: gloves and eye protection when handling strapping and compressed foam.

Operators should be trained on the difference between the rated maximum foam size and the actual chamber height, so that oversized blocks are reduced before loading rather than forced in.

Maintenance is mainly hydraulic care and housekeeping.

• Daily: clean foam dust from the chamber, the ram guides and the floor around the power unit.
• Weekly: check hydraulic oil level and look for leaks at fittings and hoses; inspect the ram face for damage.
• Monthly: check hose condition, tighten fasteners, test the guards and interlocks.
• Spare parts: keep hydraulic hoses, seals, filters and a set of fasteners in stock so that a minor leak does not stop the line for days.

Hydraulic oil should be changed according to the supplier's schedule and the working environment. In dusty workshops, filters need attention sooner than the calendar suggests.

Each machine is assembled and function-tested before shipment, including the hydraulic circuit, the stroke limit and the safety interlocks. The machine is CE certified.

For transport, the machine is cleaned, protected against corrosion and packed for container shipment. Because the machine stands 3000mm tall and weighs 2500kg, the loading plan, lifting points and container arrangement are agreed before dispatch. Delivery time is 45 working days after downpayment, and the final schedule is confirmed when the order is placed.

Three questions decide whether the TDB-01 is the right baler for a plant:

1. What is the largest block you need to bale? The rated maximum foam size is 900×700×1000mm. Larger blocks must be cut down first.
2. How much material moves per day? Match the baling rate to the output of the shredder or the volume of waste collected. Batch operation alongside a recycling line is the typical pattern.
3. How will the bale be packed and shipped? The packing method determines the restraint, and the restraint determines whether the bale survives transport.

Share your block size, daily waste volume and available floor space, and we will confirm the configuration, packing method and delivery schedule.