TDPB-A Rebond Block Foam Machine ±5kg/m³ Density 2100 mm Width for Gym Mat Production

The TDPB-A turns crushed waste foam into square rebond blocks. It mixes PU foam, rubber, EVA and EPE granules with binder in a 15 m³ tank, fills a block mold, and cures the block with steam or natural solidification. Foam density runs from 50 to 300 kg/m³, the density tolerance is held within ±5 kg/m³, and the line produces 3 blocks per hour. The standard block measures 2100 × (1100–2000) × (600–1200) mm, with 46 kW motor power and a 16 ton frame.

Two features matter to a plant buying this class of machine: the density is even from the upper to the lower part of the block, and several block widths can be produced in the same tank without changing molds. This page explains how those two results are achieved in daily production, and what to check so they stay stable.

• Model: TDPB-A
• Foam size: 2100 × (1100–2000) × (600–1200) mm
• Foam density: 50–300 kg/m³
• Density tolerance: ±5 kg/m³
• Productive capacity: 3 blocks/h
• Motor power: 46 kW
• Machine weight: 16 ton
• Overall dimension: 7695×6235×9407 mm
• Certification: CE

• Even density through the block: a ±5 kg/m³ tolerance means the upper and lower faces cut and laminate the same way, so downstream thickness stays consistent.
• Fewer mold changes: several block widths and heights run in one tank, which cuts the downtime that used to come with every size change.
• Waste-based raw material: crushed PU foam, rubber, EVA and EPE replace virgin foam and turn factory offcuts into saleable block.
• Two curing routes: steam molding for a short, repeatable cycle, or natural solidification where steam is not available.
• Stable heavy frame: a 16 ton structure holds the mold and press under repeated cycles without movement that would distort the block.
• Simple block format: square blocks are easy to stack, store and cut, and they suit both sheet production and molded parts.

1. Sort the waste. Keep PU, EVA, PE and rubber offcuts separate so a recipe can be repeated.
2. Crush. Reduce the waste to a consistent granule size. Mixed granule sizes fill the mold unevenly and show up as density variation.
3. Dose the binder. Add binder against the granule weight, not the mold volume.
4. Mix. Stir in the 15 m³ tank until the binder is spread through the batch.
5. Fill and press. Fill the block mold to the target weight for the selected size, then press.
6. Cure. Steam molding or natural solidification bonds the granules into a block.
7. Demold and cut. Remove the block and send it to cutting or lamination.

Older rebond machines often produced a block that was dense at the bottom and light at the upper face. When that block is cut into sheet, the sheet from one layer is harder than the sheet from another, and laminating or die-cutting settings have to be adjusted twice.

A ±5 kg/m³ tolerance removes that band. To hold it, three things must stay stable:

• Granule size: a consistent crush lets the binder coat each granule the same way.
• Binder ratio: dose by weight and check the scale, not the bucket.
• Fill weight: weigh the fill for each block size; a volume-only fill changes density whenever the waste bulk density changes.

Check density with samples from the upper, middle and lower part of the block. The result should sit inside the tolerance band, not just at the surface.

The standard block is 2100 mm long, 1100–2000 mm wide and 600–1200 mm high. The useful part for a plant is the middle range: a 1200 mm wide block for gym mats and a 1800 mm wide block for cow mattresses can come from the same tank on the same shift.

Size changes still need a check, even without a mold swap:

1. Set the block dimensions on the adjustable mold walls and confirm the corners are square.
2. Recalculate the fill weight for the new volume so density stays inside the tolerance.
3. Run one trial block and measure dimensions and density before the batch continues.

The trial block is the lowest-cost quality gate in the plant. It catches a wrong fill weight before a shift of blocks is out of tolerance.

Block size, density and capacity define the configuration. Confirm the waste mix and the target density band before ordering, because both affect the crusher, binder system and fill settings.

• Gym mats: rebond block cut into protective matting for fitness areas and equipment padding.
• Livestock bedding: cow mattresses and stable mats that need a firm, even block.
• Automotive interior: foam sections for seat and trim padding.
• Footwear: cushion material for midsoles and shoe components.
• Floor mats: shock-absorbing mats for entrances, workshops and sports areas.
• Decoration: rebond foam for decorative panels and shaped parts.
• Packaging: block foam cut into protective inserts and cushioning.

Binder mixing is where density problems start. The binder is measured by weight against the granule batch, then mixed long enough to coat the granule surfaces without making the mix wet enough to ball up. A mix that looks even but feels wet will press into a block with binder-rich pockets.

Fill weight is the second control. For each block size, calculate the target weight from volume and density. For a 2100×1800×1000 mm block at 120 kg/m³, the target is about 454 kg of mixed material. Weigh the fill instead of filling by volume, because the bulk density of crushed waste changes with foam type and granule size.

Record the batch weight, binder weight and fill weight for every block. When density drifts, the log shows which variable moved.

Rebond blocks are usually cut into sheet or profiled parts. A block with even density cuts with a consistent surface and a stable thickness; a block with a hard lower layer and a soft upper layer makes the blade deflect and the sheet thickness change.

For gym mats and cow mattresses, the block is split into slabs and cut to size. For automotive and shoe parts, it may be profiled or die-cut. In both routes, the block should rest after demolding until it is stable, and the cut face should show bonded granules rather than loose material.

Store blocks flat on a pallet, not on edge, and keep them dry. A block that absorbs moisture changes weight and cuts differently.

The line supports two curing routes. Steam molding gives a short, repeatable cycle and is the usual choice where a steam supply exists. Natural solidification suits plants without steam, but it takes longer, depends on ambient conditions, and keeps the mold occupied, so daily output drops.

With either route, cure is complete when the block holds its shape at demold and the cut face shows bonded granules. Demolding early deforms the block; demolding late wastes cycle time. Check the block at the mold opening before releasing it to cutting.

At 3 blocks per hour, an eight-hour shift with 80% uptime produces about 19 blocks. The mold and cure station sets the output, not the crusher, so keep a buffer of mixed granules ahead of the mold and a clear space for cured blocks behind it.

• Buffer the granules: a crusher halt should not interrupt the mold.
• Stagger cure and demold: keep the mold working while a finished block cools.
• Plan size changes at shift breaks: a trial block after each size change costs less than a rejected batch.

The frame is 7695×6235×9407 mm and weighs 16 ton, so the floor and the lifting plan come first. Keep waste storage, crusher, mixing tank and mold station in a straight flow, with crane or forklift access to the mold.

• Floor: level and load-bearing for the frame plus a full mold.
• Power: dedicated supply for the 46 kW motor; confirm local voltage and frequency.
• Steam: a stable steam line if the plant cures with steam.
• Dust: extraction or ventilation around the crusher and mixer.

Installation starts with the frame, then the mixing tank, then the mold and press. After mechanical installation, run an empty cycle and check the mold movement, press and demold sequence before loading material.

Commissioning then moves to a trial batch: crush a known mix, dose the binder, fill one block, cure and cut a density sample. That sample becomes the baseline for the shift.

Safety points:

• Lock out the crusher before clearing a jam.
• Keep hands clear of the mold press and demold area.
• Use eye and dust protection around the crusher and mixer.
• Keep the steam connection and valves clear and inspected.

Quality control is a density sample from each batch plus checks on block dimensions, squareness and binder spots. Record the waste mix, binder dose, fill weight and density in one log so a later complaint can be traced to a batch.

The machine is a 16 ton project, so shipment is planned as break-bulk or flat-rack cargo with the frame braced and the mold protected. Packaging is confirmed with each order because the right packing depends on the shipping method and destination port. Delivery time is 45 working days after downpayment; payment terms are L/C or T/T and price is quoted on inquiry.