33 kW Drive Rebonded Foam Machine and Rebonded Foam Line for 3 Blocks per Hour

The TDP-10 is a rebonded foam making line that turns shredded waste foam into blocks of 2100*1800*1000 mm at 3 blocks per hour. The whole line runs on a 33 kW motor, the machine weighs 8000 kg, the stirring tank takes a 15 m³ batch at 40 r/min, and the line footprint is 4000*4000*5400 mm. It is CE certified.

Power is where a foaming line keeps costing money after the purchase. A line that needs a large installed load pays for it every shift, in cable size, transformer capacity and electricity. The TDP-10 is built around a 33 kW drive, so the line can be installed in a workshop without a substation upgrade, and the running cost per block stays predictable.

• Model: TDP-10
• Foaming size: 2100*1800*1000 mm
• Stirring volume: 15 m³
• Stirring rate: 40 r/min
• Productive capacity: 3 blocks/h
• Motor power: 33 kW
• Machine weight: 8000 kg

1. Shred the waste. Waste foam is shredded to the size the block recipe needs.
2. Load the tank. Shredded foam and binder go into the 15 m³ mixing tank.
3. Mix. The tank stirs at 40 r/min until the binder is spread through the batch.
4. Fill the mould. The mix is transferred into the 2100*1800*1000 mm mould.
5. Cure. The block cures under the line's pressure or steam cycle.
6. Demould. The block is released, staged, and the mould returns to the fill station.

Three blocks per hour comes from the cycle, not from the motor size. Keeping the mould staged and the mix on time is what actually delivers the output figure.

The number that matters on a foaming line is energy per finished block. A 33 kW drive running a steady three-block cycle uses a calculable amount of power per block; a larger drive on the same cycle does not make blocks faster, it just draws more. That is why the TDP-10 is specified around the cycle rather than around a bigger motor.

Installed power also decides where the line can go. A 33 kW line can be connected in a workshop that would need a substation upgrade for a 75 kW line. For a plant adding recycling capacity in an existing bay, that difference is often the deciding factor between a project that starts this quarter and one that waits for an electrical upgrade.

Running cost is not only electricity. A smaller drive means smaller cable, smaller switchgear and a simpler panel, all of which reduce maintenance and spare-part stock. The trade is that the line must be run on its cycle: if the mould staging slips, output drops and the cost per block rises.

• Keep the cycle: 3 blocks per hour depends on mould staging, not on motor size.
• Check the load: an over-filled mould trips the drive; fill weight belongs in the recipe.
• Plan the electrical supply: 33 kW is a workshop connection, not a substation project.

• Low installed power: a 33 kW motor covers mixing, foaming and the line drives, which keeps the electrical installation simple.
• Predictable running cost: energy per block depends on cycle time, so a steady 3 blocks per hour gives a steady cost figure.
• Compact footprint: 4000*4000*5400 mm fits an existing bay instead of requiring a new building.
• 8000 kg structure: enough mass to hold the mixing tank and mould station in alignment.
• 15 m³ batch size: a full batch per cycle, which is what makes 3 blocks per hour possible.
• Simple maintenance: one motor, one mixing tank, one mould station, so the service list stays short.
• CE certified: export-ready electrics and guarding.

• Waste foam recycling: shredded sponge and PU offcuts turned into blocks.
• Mattress and furniture: rebonded block for cushioning and padding.
• Gym and sports mats: dense rebonded block for mat cores.
• Packaging: recycled block cut into protective shapes.
• Insulation products: rebonded block for acoustic and thermal builds.
• Carpet underlay: recycled foam block for underlay production.

Foaming faults show up after demoulding, when the block is already made. Check the mix and the binder dosing before the fill, and one wasted batch is avoided.

The line occupies 4000*4000*5400 mm, so plan the shredder feed, the binder storage and the block staging around it. The most common layout mistake is leaving no room for cured blocks, which forces the operator to stop the line while a block is moved.

Binder handling is the safety topic on a foaming line. Keep the dosing area ventilated, keep the binder containers closed, and make sure the operator knows the cure time before demoulding.

• Shredder feed: steady supply so the tank is not filled in bursts.
• Binder area: ventilated, containers closed, dosing pump calibrated.
• Mould staging: enough floor for cured blocks so the line does not stop.
• Electrical: 33 kW supply with correct protection, panel kept clear of foam dust.

The mixing tank and the dosing pump carry the quality. Check the spray pattern and the dosing calibration at the start of each shift, and clean the tank before binder build-up changes the batch. A dosing pump that is slightly off shows up as a density variation across the block, not as an obvious fault.

The mould station is the mechanical wear point. Check the release agent, the mould surface and the sealing, and keep the demoulding mechanism lubricated. A mould that starts sticking will damage block corners before it fails outright.

• Every shift: dosing calibration, spray pattern, release agent, mould surface.
• Weekly: tank cleaning, mixing blade condition, drive belt and coupling.
• Monthly: electrical check, lubrication, block density verification.
• After a recipe change: re-check dosing and cure time before the first block.

The line ships in export packing with the mixing tank, mould station and control panel separated and braced. At 8000 kg and 4000*4000*5400 mm working footprint, plan the container loading and the receiving access before the shipment date.

Delivery is 45 working days after downpayment, payment by T/T or L/C, minimum order one set. Installation guidance, remote commissioning support and spare dosing parts can ship with the line.