Rebonded Foam Machine with 2100x1800x1000 mm Mould and 15 m³ Tank Delivers

The TDP-10 forms rebonded foam blocks of 2100*1800*1000 mm at 3 blocks per hour. A 15 m³ mixing tank feeds the mould at 40 r/min, the line runs on a 33 kW motor, machine weight is 8000 kg and the overall size is 4000*4000*5400 mm. The line is CE certified.

A fixed block size is a commercial decision as much as an engineering one. If the block matches what the cutting line and the customer expect, there is no trimming, no re-cutting and no waste at the edges. The TDP-10 is built around a 2100*1800*1000 mm mould, so every block is the same size and the downstream cutting plan does not change from batch to batch.

• 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 and load. Shredded waste foam goes into the 15 m³ tank with the binder.
2. Mix at 40 r/min. Run the full mixing time so the binder reaches the whole batch.
3. Fill the mould. Transfer the batch into the 2100*1800*1000 mm mould.
4. Cure. Hold the block for the recipe cure time.
5. Demould and stage. Release the block, move it to staging, return the mould.
6. Repeat. Three cycles per hour delivers the output figure.

Output is a staging question. If the cured block is not moved promptly, the mould waits and the third block of the hour slips into the next one.

Trimming is the hidden cost in recycled foam. If blocks arrive in random sizes, the cutting line has to square them first, and the offcuts go back to the shredder. That is labour, machine time and material all spent before a sellable sheet exists. A fixed 2100*1800*1000 mm block removes that step for plants whose downstream equipment is set up for that size.

A fixed size also makes output quotable. Three blocks per hour is an easy number to plan a shift around, and it converts directly into square metres of finished sheet once the cutting plan is known. Sales can quote a delivery date from the block count rather than from a guess.

The constraint is flexibility. A single mould size suits a plant with a stable product mix; a plant that changes block sizes weekly needs a different mould arrangement. That is a purchasing decision to make before the order, not after.

• Match the cutter: the block size should be what the downstream line already handles.
• Plan staging: three blocks per hour needs floor space for cured blocks.
• Decide the mould before ordering: one size suits a stable product mix.

• Fixed block size: 2100*1800*1000 mm on every cycle, which keeps the cutting plan stable.
• 3 blocks per hour: a predictable output figure for planning and for quoting delivery.
• 15 m³ batch: one mix per block, so the block is not a blend of two batches.
• 40 r/min mixing: binder is spread through the batch before the fill.
• No trimming: blocks that match the cutter reduce waste and re-processing.
• 33 kW drive: the line runs on a workshop supply rather than a substation upgrade.
• CE certified: export-ready guarding and electrics.

• Mattress core blocks: fixed size for a stable cutting plan.
• Furniture cushioning: block cut into pads without edge waste.
• Gym mats: consistent block for repeat thickness.
• Carpet underlay: block sized for the splitting line.
• Packaging shapes: block that machines predictably.
• Recycling operations: waste foam converted to a standard block.

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.

Plan the shift around the cycle: shred supply, binder dosing, fill, cure and demould. The three-block hour only happens when the staging area is clear and the shredder keeps up with the tank.

Safety on a foaming line is mostly binder handling and moving blocks. Keep the dosing area ventilated, and use a lift or a block grab for a cured block rather than dragging it across the floor.

• Shred supply: enough shredded foam staged for the shift.
• Staging area: floor space for at least three cured blocks.
• Binder area: ventilated, containers closed, dosing calibrated.
• Block handling: lift or grab, never drag a block across the floor.

The mould is the part that decides whether the block size stays on spec. Check the mould surface, the sealing and the release agent at the start of each shift. A worn seal lets foam flash into the joint, and the block comes out oversize at one edge.

The mixing and dosing side decides density, and density decides whether the block sells as the grade it was made for. Calibrate the dosing pump each shift and clean the tank at the end of the run.

• Every shift: mould surface, seal, release agent, dosing calibration.
• Weekly: demoulding mechanism, stirrer blade, spray nozzle.
• Monthly: drive check, panel dust, block dimension and density verification.
• After a mould change: check the first block for size before running the 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, plan the container loading and the access at the receiving site before the shipment date.

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