8-50 kg/m³ Continuous Foaming Machine with 3000 kg/h Capacity for Flexible PU Blocks

The TDP-1500 pours flexible PU foam from 8 kg/m³ to 50 kg/m³ on the same machine. Foaming diameter is 1.2-1.5 m, production capacity is 3000 kg/h, foaming flow is 90 L/min, total power is 56 kW and machine weight is 12000 kg. The machine is CE certified.

A foam plant that sells one density lives or dies with that market. A plant that can pour 8 kg/m³ soft foam for packaging in the morning and 45 kg/m³ foam for furniture in the afternoon keeps the same line earning across more orders.

The density range is a metering question, not a marketing one. The two chemical streams have to hold their ratio through the whole block, and the lift speed has to follow the flow so the block does not compact at the base or turn spongy at the top. The TDP-1500 is set up for 8-50 kg/m³ with the recipe stored in the PLC.

• Model: TDP-1500
• Density range: 8-50 kg/m³
• Foaming diameter: ⌀1.2-1.5 m
• Output: 3000 kg/h
• Foaming flow: 90 L/min
• Total power: 56 kW

1. Recall the recipe. Load the stored ratio and flow for the density being poured.
2. Flush the head. Clear the previous component before the first block of the new recipe.
3. Set the lift speed. Match the slower pour at the dense end of the range.
4. Pour a check block. Weigh the first block and compare against the target density.
5. Adjust the ratio. Trim the metering pumps if the weight is outside tolerance.
6. Log the recipe. Store the corrected setting so the next run starts on target.

A 1% density error on a 3000 kg/h line is 30 kg of chemical an hour. Weigh the first block of each shift, not each month.

Most density claims fail at the top of the block, not the bottom. The pour starts cold, the flow settles, and if the lift speed was set from the first minute of the run, the upper section ends up lighter than the base. The weight check on the finished block is what catches it.

Temperature is the second cause. Component viscosity moves with temperature, so a recipe that held 25 kg/m³ in the morning can run light after the plant warms up. Storing the recipe and checking the block weight keeps the range usable across a shift.

The third cause is the foam formulation itself, not the machine. Fillers and catalysts affect how the foam rises, so the metering recipe has to be tuned with the customer chemical supplier, then locked in the PLC.

• Range: 8-50 kg/m³ across one head.
• Control: stored recipes and block weight checks.
• Stability: lift speed follows flow, not the operator.

• 8-50 kg/m³ window: one machine covers soft, medium and high density recipes by changing the metering recipe.
• Stored recipes: density changes are recalled from the panel, not re-set by hand.
• 3000 kg/h output: output holds at the dense end of the range, where the pour is slower.
• ⌀1.2-1.5 m blocks: the cylinder diameter keeps peel waste low when blocks are converted into sheets.
• PLC control: lift and rotation settings repeat on the next block.
• Low labour demand: two operators cover the pouring station once the recipe is set.
• CE certified: export-ready guarding and electrics.

• Mattress foam plants: cylinder blocks poured for peeling into mattress and topper sheets.
• Furniture foam: sofa and cushion foam blocks in medium and high density.
• Shoe material foam: soft foam blocks for insole and lining stock.
• Bra and garment padding: low density soft foam for padding stock.
• Electronics packaging: protective foam blocks cut into inserts.
• Automobile interior: seat and trim foam blocks poured in the same line.

• Lock out the foaming head before any nozzle or trough work.
• Keep the lifting table zone clear while the pour is running.
• Vent the foaming room and monitor isocyanate exposure.
• Follow the pressure relief sequence before opening any chemical line.

• Flush the mixing head at the end of every shift.
• Check the metering pump seals weekly for weeping.
• Inspect the lifting chain and guides monthly.
• Keep the PLC recipe backup in the maintenance file.

The machine travels in an export-grade wooden case with the electrics protected and the cutter or blade assembly braced separately. Machine weight is 12000 kg and the overall dimension is 4000*6000*8500 mm, so the unit is quoted against a 20ft or 40ft container depending on the line it ships with.

A packing list, wiring diagram, operation manual and CE declaration travel with every unit. Delivery is 45 working days after downpayment; installation and commissioning support is available remotely or on site.