±5 kg/m³ Rebond Foam Machine with 15 m³ Tank and 4 Blocks/h Output

The C619 is a rebond block foaming machine that holds block density within ±5 kg/m³ up to 120 kg/m³. The mixing tank is 15 m³, the foaming tank is supplied in two customized dimensions, output is 4 blocks per hour on a 33.5 kW drive, and the machine weighs 15 t. It is CE certified.

A rebond block is sold on density. The customer orders 80 kg/m³, cuts it into mat or sheet, and measures again; if the block is 75 at one end and 88 at the other, the order is rejected even though the average looks right. Density tolerance is the number that decides whether a rebond line is sellable.

• Model: C619
• Mixing tank: 15 m³
• Capacity: 4 blocks/h
• Density: ≤120 kg/m³
• Tolerance: ±5 kg/m³
• Motor power: 33.5 kW
• Weight: 15 t

1. Weigh the granule. Charge the granule to the batch weight; the scale is the first control.
2. Dose the binder. Add binder by weight for the target density, not by eye.
3. Mix in the 15 m³ tank. Run the full mixing time so the binder is distributed through the batch.
4. Fill the foaming tank. Transfer to the mould with the tank dimension set for the block order.
5. Cure and demould. Allow the full cure time before the block is handled.
6. Weigh and record. Weigh each block and record the density against the order.

Record the block weight, not only the setting. A block that is 3 kg heavy on a 120 kg/m³ order is a density error that shows up when the customer cuts it, and the record is what tells you the dosing has drifted.

Rebond density is set by the ratio of granule to binder and by how evenly that binder is spread. Two batches can have the same total weight and still produce different blocks if the mixing time is short and the binder sits in pockets.

The 15 m³ tank is what makes even distribution possible at this output. A small tank forces short mixes to keep up with 4 blocks per hour, and short mixes are exactly where density variation comes from.

Cure time is the second control. A block that is demoulded early compresses under its own weight and comes out denser at the bottom than at the top, which reads as a density tolerance failure even though the recipe was correct.

• Weigh both components: granule and binder, every batch.
• Mix the full time: a 15 m³ batch needs its mixing time, not a shortened one.
• Cure before handling: early demoulding shows up as a dense bottom.

• Density held within ±5 kg/m³: the tolerance that matters when the block is cut and re-measured.
• Range up to 120 kg/m³: covers mat, underlay and cushioning grades.
• 15 m³ mixing tank: consistent binder distribution across a full batch.
• 4 blocks per hour: output matched to a working cutting line downstream.
• Two foaming tank options: block size specified to the market being served.
• 33.5 kW drive: mixing power held through a full batch, not just at start-up.
• CE certified: export-ready guarding and electrics.

• Gym mats: blocks cut into mat with a fixed density.
• Carpet underlay: rebond blocks to a specified density.
• Cushioning: blocks for seating and padding.
• Packaging blocks: recycled foam blocks for protective packaging.
• Insulation panels: blocks cut into panel.
• Foam recycling: offcut and granule conversion into sellable blocks.

Rebond density problems are almost always dosing or mixing time. Weigh the granule and the binder, mix long enough for the batch size, and check one block from each shift rather than one block per week.

Binder dosing is the safety-critical step as well as the quality-critical one. Keep the dosing area ventilated, follow the binder supplier's handling instructions and keep the mixing area clear while a batch is running.

The foaming tank and mould station are hot and under pressure during cure. Keep the guarding in place and do not open a mould before the cure time has elapsed.

• Batch sheet: granule weight, binder weight, mixing time, block weight.
• Ventilation: dosing and mixing area ventilated per the binder data sheet.
• Guarding: foaming tank and mould station guards in place.
• Cure discipline: no demoulding before the specified cure time.

Clean the mixing tank and the outlet on a fixed schedule. Binder residue in the tank changes the ratio of the next batch and granule build-up at the outlet reduces output.

Check the weighing system monthly against a known weight. A scale that is 1% out produces a density error that is invisible on the batch sheet but obvious in the finished block.

• Every batch: tank and outlet condition, block weight logged.
• Weekly: mixer blades, seals, binder pump.
• Monthly: scale calibration, motor current, guard check.
• Every block: weigh and record; check the trend weekly.

The line ships in export packing in major assemblies, with the mixing tank, foaming tank and control cabinet packed separately. At 15 t total, plan the crane or forklift capacity and the container loading sequence before shipment.

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