C818A Infinite Long PU Foam Loop Horizontal Cutting Machine 1100-2300 mm Width

Infinite Long Loop Foam Cutting Machine with 1100-2300 mm Width and 1300 mm Height for Continuous PU Foam Production

The C818A is an infinite long foam loop horizontal cutting machine built on a linear motion guide structure, designed for continuous production of thin PU foam sheet. A closed-loop cutting path replaces the load-cut-unload cycle of a conventional slicer, so a long foam block is fed through the blade and the sheet arrives at the outfeed side without being released between passes.

The working range is set for industrial sheet production: cutting width 1100–2300 mm, cutting height 1300 mm, cutting thickness 0.6–170 mm and cutting speed 60–130 m/min. Cutting precision is ±0.1 mm in the 0.6–5 mm thin-sheet window — the range where mattress layers, laminating substrates and packaging inserts are won or lost.

The machine is heavy by design: main motor power 131 kW, machine weight 60 T and an overall dimension of 33000×7000×8500 mm. A frame of that mass and length is what allows 24-hour continuous running without the cutting position drifting as the structure warms up and vibrates.

It handles PU sponge in the 15–50 kg/m³ density band, and it is aimed at mattress and furniture plants, packaging converters, lamination processors and large sponge factories that measure output in shifts of continuous sheet rather than in single blocks.

A production run follows a short sequence, and the repeat cycle that dominates a conventional slicer has been removed from it.

1. Load the block once. The foam block is placed on the infeed section and aligned against the reference edge.
2. Set thickness and speed. Sheet thickness is set in the 0.6–170 mm range, and cutting speed in the 60–130 m/min range according to density and thickness.
3. Start the loop. The closed-loop path carries the block through the blade and returns the cut sheet to the outfeed side.
4. Run continuously. The next pass starts without the operator releasing, lifting or re-clamping the block.
5. Collect sheet. Finished sheet is taken from the outfeed side and stacked or transferred to lamination.
6. Change specification. A new thickness or speed is entered, and the run continues on the same block.

Steps four and six are where the labour saving sits. On a reciprocating slicer, every sheet ends with a return stroke and a handling action; on this machine the block keeps travelling and only the setting changes between specifications.

A conventional horizontal slicer works in one direction and then returns. The return stroke produces no product, and the block has to be handled at the end of each pass. Both costs are inside the cycle time, and both scale with the number of sheets.

The C818A closes the path into a loop. The block passes the blade, the sheet is taken off at the outfeed side, and the carriage continues around to the start of the next pass. The operator loads once and unloads sheet, instead of loading, clamping, cutting, releasing and re-clamping for every sheet.

That change has three visible effects in a plant:

• Labour: one operator manages the line rather than one operator per machine position, because the machine does the handling between passes.
• Material loss: fewer clamps and fewer re-positioning steps mean less trim at the block ends and fewer damaged sheets at the start and finish of a cut.
• Consistency: the block stays in the same reference position from the first sheet to the last, so the thickness does not drift with repeated re-clamping.

The 59–65 m cutting length is part of that logic: a long loop gives the block time to stabilise between passes and gives the outfeed side room to accumulate sheet without halting the run.

Thin sheet exposes machine behaviour that thick blocks hide. A vibration of a fraction of a millimetre that would be invisible in a 100 mm block becomes a visible thickness wave in a 2 mm sheet, and a wave like that shows through after lamination as a line across the finished panel.

That is the reason for the guide choice and the frame mass. The linear guide keeps the cutting path straight over 33 m, the reinforced anti-fatigue frame keeps the geometry under a continuous load, and the anti-vibration structure removes the offset that appears when a machine runs at speed for hours rather than minutes.

• Thickened reinforced frame: an anti-fatigue welded structure sized for 24-hour continuous production, carrying the loop and the guide rails without deflection.
• Linear motion guide system: the carriage runs on linear guides along the machine length, which holds the blade path straight and reduces wear compared with sliding ways.
• Closed-loop cutting path: the return path is part of the working cycle, so the block is not released between passes.
• Anti-vibration cutting head: an anti-offset structure that keeps the sheet thickness stable at 60–130 m/min.
• Wear-resistant transmission: high wear-resistant drive components chosen for continuous duty rather than for peak load.
• Infeed and outfeed sections: long support surfaces that keep a full block aligned and give the outfeed side room to accumulate sheet.
• Control panel: thickness and speed settings, with the run controlled from a single station.

The 33000 mm length is the defining structural fact of this machine. A frame that long has to be straight, level and stable, because any twist along the guide translates into a thickness error that varies from one end of the sheet to the other.

The precision figure is stated for the 0.6–5 mm window, because that is where the tolerance is critical for downstream lamination. Thicker sheet in the same machine carries a wider practical tolerance, and the thickness range extends to 170 mm for thicker layers and cushioning stock.

A 0.6–170 mm thickness range on one machine covers three product groups that are normally bought as separate equipment.

Thin sheet, 0.6–5 mm. The precision window, held at ±0.1 mm. This is mattress comfort layer, laminating substrate, quilt backing and packaging facing material. Thin sheet needs a sharp blade, a stable frame and a constant feed; it is also where the anti-vibration design earns its cost.

Medium sheet, 5–60 mm. The everyday range for mattress cores, sofa cushion layers and packaging inserts. Speed can be raised toward the upper end of 60–130 m/min according to density, because thickness variation of a tenth of a millimetre matters less here than output.

Thick section, 60–170 mm. Support layers, firm cushioning and industrial padding, where the limit is the block height of 1300 mm and the feed resistance through dense foam.

Setting the machine for thin sheet and for thick section are two different jobs. Thin sheet asks for a slow, constant feed and a blade in fresh condition; thick section tolerates a faster feed but loads the blade and the drive harder.

The machine is specified for PU sponge in the 15–50 kg/m³ density band, which covers the soft and medium grades used in mattress, furniture and packaging production.

• Low density, 15–25 kg/m³: soft foam for packaging and comfort layers. It compresses easily, so feed rate and blade condition decide if the sheet arrives flat.
• Medium density, 25–40 kg/m³: mattress and furniture grades, the main working range for this machine.
• Higher density, 40–50 kg/m³: firm foam for support layers and industrial padding, where the drive and the blade tension carry more load.

Foam outside this density band, and foam containing hard inclusions, abrasive fillers or metal inserts, should be discussed before an order is placed. Those materials change blade life and load on the drive in ways that are better planned than discovered.

• Mattress and furniture: continuous PU foam sheet for mattress layers, sofa cushions and furniture padding, where sheet is fed directly into lamination or quilting.
• Packaging: uniform continuous sheet for shockproof inserts, cut to width and laminated or die-cut afterwards.
• Sponge lamination: long sheet for film and fabric bonding, where thickness consistency decides if the laminate line runs without adjustment.
• Large sponge factories: continuous slicing duty at volume, replacing a bank of reciprocating slicers with one closed-loop line.

All four applications share one requirement: the sheet has to arrive at a constant thickness for hours, not for a demonstration. That is the difference between a machine that passes a sample test and one that runs a shift.

The decision normally comes down to how many sheets per shift leave the machine. Below a certain volume, a reciprocating slicer and its lower investment is the sensible answer. Above it, the return stroke and the handling between passes become the constraint, and the loop machine pays for itself through labour and yield rather than through a higher peak speed alone.

A plant can also run both: a reciprocating slicer for short runs and odd sizes, and the loop line for the standard sheet programme that repeats every week.

• Power: a dedicated supply matching the 131 kW main motor, with correct earthing and stable voltage. The electrical configuration is confirmed for the destination market at order stage.
• Floor: a level, reinforced concrete floor able to carry 60 T over a 33000×7000 mm footprint. A frame of this length needs a floor that is flat along its whole run, not only at the load end.
• Building: a clear height above 8500 mm and a door or opening large enough for the frame sections to enter the hall.
• Layout: space at the outfeed side for sheet accumulation and for the next process, plus access along the guide for cleaning and blade changes.
• Dust: foam dust is produced along the cut, so a collection point near the blade and a regular cleaning routine keep the guides clear.

The building check should happen before the order, not after. A 33 m frame that cannot pass through the door, or a floor that slopes along its length, turns a straightforward installation into a civil works project.

The machine ships in frame sections with a layout drawing, foundation plan, wiring diagram and operation manual. Installation is done with local rigging, followed by alignment along the full length: the guide has to be set level and straight before the carriage is run.

Commissioning covers guide alignment, blade tension and tracking, thickness calibration and a trial run at working speed. A block of the customer's own foam is cut through the thin-sheet window and measured, which is the point where the ±0.1 mm figure becomes a setting rather than a catalogue value.

Training covers block loading, thickness and speed entry, sheet take-off, blade checks and the daily cleaning routine. Because the machine handles the cycle between passes, a new operator is productive quickly; the skill to learn is reading the sheet, not driving the carriage.

The cutting path is enclosed by guarding and the loop runs continuously during production, so nobody needs to stand at the blade to feed material. Guards are interlocked and the cycle cannot start with a guard open.

Three rules cover the working routine:

• Keep clear of the loop path while the machine is running, including the return section behind the blade, which is easy to forget on a long frame.
• Keep the guides and the infeed surface clear of off-cuts and loose foam, because a chip under the block changes the sheet thickness at that point.
• Check blade condition and tension at the start of each shift, before the first block is loaded.

At the end of a shift the routine is to clear dust from the blade area and the guides, confirm that no off-cut is left on the infeed surface, and record the sheet count and thickness setting so the next shift starts on the same parameters.

• Every shift: blade condition and tension, guide cleanliness, infeed and outfeed surfaces clear.
• Weekly: guide lubrication, carriage tracking check, drive belt and coupling inspection.
• Monthly: frame alignment spot check along the length, electrical cabinet cleaning, wear-part measurement on the transmission.
• Consumables: blades, guide components and wear-resistant transmission parts, stocked for replacement without waiting for an import.

On a long machine, alignment is the maintenance item that decides quality. Wear on the guide does not fail suddenly; it opens the thickness tolerance gradually from one end of the frame to the other, and the first sign is usually a customer complaint about sheet that varies within the roll.

Each machine is assembled, aligned and run before shipment. The inspection covers guide straightness along the frame, blade tension and tracking, carriage travel, control response and a sample cut measured across the sheet. The inspection record is supplied with the machine.

Because the frame is 33000 mm long, it ships in sections with rust-proof treatment and protected guide surfaces; the control cabinet and small components go in wooden cases and are labelled against the layout drawing. The shipping plan and the sequence of assembly on site are confirmed before dispatch.

Standard delivery is 45 working days after the down payment is confirmed, shipped from Qingdao port. Payment terms are T/T or L/C, minimum order quantity is one set, and supply ability is three sets per season. The electrical configuration is CE compliant for European and other export markets.