15 m³ Rebonded Foam Machine with 40 r/min Stirring and 3 Blocks/h Output

Density variation in a rebonded block starts in the mixing tank. The TDP-10 stirs a 15 m³ batch at 40 r/min, fills a 2100*1800*1000 mm mould, and runs 3 blocks per hour on a 33 kW drive. Machine weight is 8000 kg, overall size 4000*4000*5400 mm, and the line is CE certified.

A block that is dense at one end and light at the other cannot be sold as one grade. The cause is almost always binder distribution: if the spray does not reach every part of the batch, some shredded foam is coated and some is not. A 15 m³ tank with a 40 r/min stirrer is sized to keep a full batch moving so the binder reaches the whole volume before the fill.

• 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. Prepare the shred. Shredded foam goes in at the size the recipe calls for.
2. Load the tank. Fill the 15 m³ tank to the batch weight for the block.
3. Start the stirrer. The tank turns at 40 r/min and the binder is sprayed into the moving batch.
4. Complete the mix. Run the full mixing time so the binder reaches the bottom and the tank walls.
5. Fill the mould. Transfer the batch into the 2100*1800*1000 mm mould in one fill.
6. Cure and demould. Cure for the recipe time, then release the block and reset the mould.

The mixing time is not a formality. Stopping the cycle early leaves part of the batch under-coated, and that shows up as a soft end on an otherwise good block.

Density variation in a rebonded block has three usual sources: uneven binder coverage, uneven shred size, and a fill that separates the mix. Binder coverage is the most common. If the spray is concentrated in one part of the tank, the foam there bonds tightly and the rest of the block is loose.

Shred size matters because the binder coats surface area, not weight. A batch with a wide spread of shred sizes has a wide spread of surface area, so the same binder quantity produces a different bond from particle to particle. Keeping the shred size consistent is the cheapest way to keep the block density consistent.

The fill is the third source. A batch that sits after mixing can separate, with heavier wetted foam settling. Filling promptly after the mix, in one pass, is why the tank volume and the mould volume are matched on this line.

• Spray coverage: check the pattern across the full tank, not just at the centre.
• Shred size: consistent shred gives consistent surface area and consistent bond.
• Fill promptly: a batch that waits can separate before it reaches the mould.

• One batch per block: a 15 m³ mix fills the 2100*1800*1000 mm mould from a single batch.
• 40 r/min stirring: the batch keeps moving long enough for the binder to reach every particle.
• Even density: the result is a block that measures the same at the top, bottom and two ends.
• Dosing control: the pump can be calibrated per recipe, so a density change is a setting rather than a trial.
• 3 blocks per hour: the mixing cycle is timed to the mould cycle, not to the tank size.
• 33 kW drive: full-batch mixing without a large installed load.
• CE certified: export-ready electrics and guarding.

• Rebonded block for mattresses: even density for consistent feel across the block.
• Furniture cushioning: block that cuts predictably into pads.
• Gym mats and sports flooring: consistent density for impact performance.
• Carpet underlay: uniform block for repeat thickness.
• Packaging shapes: block that machines without soft spots.
• Acoustic panels: density-controlled block for sound absorption.

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.

Each recipe should have a written card: shred size, batch weight, binder quantity, mixing time and cure time. Operators should work from the card rather than from memory, because a small change in binder quantity is invisible until the block is cut.

Binder handling and ventilation are the safety items. Keep the dosing area ventilated, keep containers closed, and never demould a block before its cure time to gain output.

• Recipe card: one per product, covering shred size, batch weight and binder quantity.
• Dosing check: calibrate the pump at the start of each shift.
• Ventilation: keep the binder area ventilated and containers closed.
• Cure discipline: no early demoulding to chase output.

Clean the tank at the end of a run. Binder build-up on the tank wall reduces the effective volume and changes the mixing pattern, which shows up as density variation long before anyone suspects the tank.

Check the stirrer blades and the spray nozzle weekly. A worn blade leaves a dead zone at the bottom of the tank, and a partly blocked nozzle leaves a dry patch in the batch. Both are cheap to fix and expensive to ignore.

• Every shift: dosing calibration, spray pattern, tank condition.
• Weekly: stirrer blades, nozzle, tank wall build-up.
• Monthly: drive coupling, panel check, density verification on a cut block.
• After a recipe change: re-calibrate dosing before the first batch.

The line ships in export packing with the tank, mould station and panel separated and braced. At 8000 kg and 4000*4000*5400 mm, confirm the container plan 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 and remote commissioning support are included.