TDC-01 6.14kW Digital Control Long Foam Block Cutting Machine for Continuous Foam Blocks

 Digital Control Long Foam Block Cutting Machine for Continuous Foaming Line with 1300mm Cutting Height

Product Introduction

The TDC-01 digital control long foam block cutting machine cuts continuous foam blocks to a set length online, immediately after the foaming line. The operator enters the target length on the digital control, and the gantry cutter automatically separates the continuous block into uniform, fixed-size pieces. It handles blocks up to 1300mm high and 2300mm wide with a 6.14kW motor, and its heavy-duty welded gantry frame keeps the cut square through long production runs.

Continuous foaming produces a foam block that keeps growing until the run ends. The block is long, and the downstream process needs it in fixed lengths: mattress cores, sofa foam, packaging blanks and deep-processing inputs all start from a block of a defined size.

Cutting that block by hand leaves the length to the operator's judgement and the square to the eye. The TDC-01 replaces that judgement with a setting. The cutting length is entered on the digital control, the machine indexes the block, and the gantry blade cuts square to the block axis. Every block comes out at the same length, which is what makes the downstream cutting and lamination steps predictable.

The machine is designed as supporting equipment for continuous PU foaming lines. That means the frame height, the cutting width and the control interface are chosen around the block that a foaming line actually produces, not around a general-purpose workshop job.

In a continuous foaming line, the foam rises on a conveyor and forms an endless block. The block leaves the foaming tunnel and must be divided before it can be stacked, stored or processed. This is the point where the TDC-01 sits.

• Timing. Because cutting happens inline, the machine works at the pace of the foaming line rather than at the pace of a separate shift. When the block moves, the cutter indexes to the set length and cuts.
• Length setting. The operator enters the target length digitally. Changing from one block length to another is a setting change, not a mechanical rebuild, so a line can run several block sizes in one campaign.
• Squareness. The gantry structure carries the blade across the block in a straight line, so the end face is square to the sides. A square block stacks better and cuts better downstream.

For plants that already run a foaming line, the TDC-01 removes the manual cut-off station and the labour attached to it. For plants planning a new line, it should be sized together with the foaming tunnel so that the cutter matches the block section and the line speed.

Cut length is the parameter that decides material yield. A block cut 10mm long wastes foam on every piece; a block cut 10mm short fails the customer's specification. Digital control removes the guesswork from both ends.

• Set the length, not the stop: the target length is entered on the control, and the machine indexes to it.
• Repeatability: the same setting produces the same length on the first block and on the last block of the run.
• Changeover: switching from one block size to another takes a setting change, which matters when a line runs mixed orders.

The control also gives the operator a clear interface for start, stop and cut commands, so the cut sequence can be run from one station instead of from two ends of the machine.

The TDC-01 is a gantry machine. The cutting head travels on a bridge that spans the block, and the frame carries the load of the cut rather than relying on the block itself for support.

• Heavy-duty frame. The frame is a solid welded structure, built to stay rigid while cutting large blocks. Rigidity is what keeps the blade tracking straight when the cut meets a denser section of foam.
• Cutting envelope. Maximum cutting height is 1300mm and maximum cutting width is 2300mm, which covers the large PU foam blocks produced by continuous foaming. The overall dimension is 4200×1300×3800mm and the machine weighs 1000kg.
• Motor. A 6.14kW motor drives the cutting system. The power is matched to the block section: enough to carry the blade through a full-height cut without stalling, without oversizing the drive for work the machine does not do.

• Digital length control: digital setting for cutting length, high cutting accuracy and uniform foam block size.
• Perfect matching: designed as supporting equipment for continuous PU foaming lines, realising inline automatic cutting.
• Heavy-duty gantry structure: solid welded frame, stable operation for large foam blocks and a long service life.
• Large cutting range: maximum cutting height 1300mm and width 2300mm, suitable for big PU foam blocks.
• Changeover by setting: switching block length is a control change, not a mechanical rebuild.
• Global support: remote technical assistance, spare parts supply and installation guidance.

• Mattress and furniture foam production: cut continuous foamed PU foam into standard blocks for mattress and sofa processing.
• Foam packaging industry: fixed-length cutting of large foam blocks for shock-proof packaging raw material.
• Foam deep processing plant: supporting the cutting stage of a continuous foaming production line.
• Block stock preparation: producing uniform blocks for later slicing, profiling or lamination.

The TDC-01 is a link between foaming and everything that follows.

• Upstream: a continuous PU foaming line produces the endless block. The block section must fit within the machine's cutting height of 1300mm and width of 2300mm.
• The TDC-01: the continuous block is cut to the set length. This is the step that converts a continuous process into discrete, storable, saleable blocks.
• Downstream: blocks go to horizontal slicing for sheets, to contour cutting for shaped parts, to lamination or to packaging. Every downstream machine works better with a square, uniform block, which is exactly what inline cutting with a fixed length produces.

Because the machine sits inline, its reliability matters more than its peak speed: a cutter that stops takes the foaming line with it.

Planning around the TDC-01 starts from the foaming line, not from the cutter.

• Line pace: the cutter must be able to divide blocks at the rate the foaming line produces them. If the cutter becomes the bottleneck, the line has to slow down.
• Block length: shorter target lengths mean more cuts per metre of foam and more cutting cycles. The digital control makes the change easy, but the cycle count still rises.
• Block section: a full-height, full-width cut at 1300×2300mm takes longer than a partial cut, so the machine's practical rate depends on the block size being produced.
• Changeover: plan orders so that block lengths change in batches rather than repeatedly within a shift.

The practical approach is to confirm the relationship between line speed and cut cycle at commissioning, then set the production plan around the slower of the two.

• Length accuracy: a manual cut-off depends on the operator's mark and hand; digital setting gives the same length every time.
• Squareness: a gantry frame holds the blade square across a 2300mm wide block; a hand-guided blade tends to drift.
• Labour: inline cutting removes a dedicated operator at the cut-off point.
• Integration: a workshop cutter is a separate step with its own handling; the TDC-01 works at the foaming line, before the block is moved.
• Block quality: uniform, square blocks reduce rejects at the slicing and lamination stages, which is where the real cost of a bad cut appears.

The machine is 4200mm long and 3800mm high, so it must be planned into the line layout.

• Line position: install the cutter immediately after the foaming tunnel outlet, with the cutting plane square to the direction of block travel.
• Floor: a level, load-bearing floor that can support the 1000kg machine and the block being handled.
• Height clearance: the machine stands 3800mm tall, and the gantry needs clearance above for maintenance.
• Power: a supply sized for the 6.14kW motor with correct protection. Confirm local voltage and frequency before the order is fixed.
• Access: space on both sides for blade changes, cleaning and inspection, and a safe walkway clear of the block path.

Commissioning covers alignment with the foaming line, a dry run, trial cuts at several lengths, a squareness check, then operator training.

• Before starting: confirm the target length, check the blade and guards, and verify that the block path is clear.
• During cutting: never reach into the gantry zone while the blade is moving. Stay outside the marked cutting area.
• Block handling: cut blocks are heavy. Use the approved handling equipment and keep hands away from the cut face.
• Lockout: isolate power before changing the blade, clearing a jam or entering the gantry area.
• PPE: gloves and eye protection when handling blades and blocks.

• Daily: clean foam dust from the blade, the guide rails and the gantry; check that the blade is undamaged.
• Weekly: inspect the blade edge, check the digital control readings against actual block lengths, and confirm that the gantry moves smoothly.
• Monthly: check the motor current against the commissioning record, inspect belts and fasteners, and test guards and the emergency stop.
• Spare parts: keep blades, blade fixings, guide wear parts and control sensors in stock so that a minor fault does not stop the foaming line.

Each machine is assembled and run before shipment, covering the gantry motion, the digital length control, the blade drive and the safety guards. The machine is CE certified.

The machine measures 4200×1300×3800mm and weighs 1000kg. It is cleaned, protected against corrosion and packed for container shipment, with the gantry and control panel protected against transit damage. Delivery time is 45 working days after downpayment, with the final schedule confirmed when the order is placed.

1. Block section: confirm the height (up to 1300mm) and width (up to 2300mm) produced by your foaming line.
2. Length range: list the block lengths you sell, so that the digital control is set up for your range.
3. Line pace: share the foaming line speed so that the cutting cycle can be matched.
4. Layout: confirm the available length after the foaming tunnel and the height clearance for a 3800mm machine.

Send these details and we will confirm the configuration, the inline layout and the delivery schedule.