8-120 kg/m3 Continuous Foaming Machine with 18m Oven Rack and 37kW Mixing Head

Core Advantages

Technical Specifications

Primary Applications

Fitting the Line into an Existing Hall

Many plants buy this build to replace a batch station inside a hall that was never laid out for a continuous line, so the layout work starts before the foundation is poured. Three distances decide if the hall works: the clear run in front of the mixing head, the walkway along the panel section, and the forklift route at the discharge end. Get one of them wrong and the line runs, but every block costs an extra move.

• Keep 1200 mm clear along the operator side of the panels; a narrower walkway turns a simple panel adjustment into a climb.
• Leave the head end open to a drum store, because chemical drums have to reach the pumps without crossing the block path.
• Plan the curing bay off the discharge end, sized for one shift of block at the target output.
• Route the wash point drain away from the block path; wash water carries residue and a wet floor beside the panels is a slip risk.
• Check headroom over the panel section for the rising wall and for service access with the wall at full height.

Utilities and Services Checklist

From Recipe Sheet to Repeatable Block

1. Confirm the ratio on water at the head before any chemical reaches the mixing chamber.
2. Set panel width and rise height for the block size, then lock the panel position.
3. Pour a narrow strip, weigh it, and correct the ratio while the strip is small enough to scrap.
4. Start the block at the lower end of the belt speed range for that grade.
5. Increase belt speed only after the block has cured through at the discharge end.
6. Log head pressure, belt speed, block height and hall temperature at 30 minute intervals.
7. Sign the recipe sheet with the values that worked and keep it at the cabinet for the next shift.

What Drives Cost per Kilogram

Two plants running the same grade on the same line can sit 8 percent apart on cost per kilogram, and the gap rarely comes from the chemical price. It comes from how much of each block is sold as slab. A block that is 4 mm out of height over its length loses that 4 mm on every slice, and on a 1200 mm block that is a visible share of the yield.

• Panel parallel to the rack: a panel that is out of parallel skins one edge heavier and the saw takes the difference off the full block.
• Belt speed against cure time: block cut early takes a set and the base goes wedge shaped.
• Rack level: a rack settled at one end produces a block thicker at that end, and the saw corrects on every slice.
• Curing bay discipline: block stacked too soon deforms under its own weight and the deformation is cut away as waste.

None of the four needs new equipment. All four show up in the block height measured at four points along the length, which is why that reading belongs on the shift sheet next to the belt speed.

Hall Temperature and the First Block of a Shift

Foam reacts slower in a cold hall, and the first block of a morning shift is where that shows. A line that ran at 3.2 m/min the previous afternoon may need 2.8 m/min at 7 am in a hall that has cooled overnight, because the block needs longer before it has cured through. Plants that log hall temperature next to belt speed spot the pattern within a week and avoid scrapping the first block. Where the hall is heated, the effect is smaller but not zero: the drum temperature of the polyol matters as much as the air, and a drum that sat cold overnight will change the ratio for the first pour unless it is brought to working temperature first.

Acceptance Test Before You Sign

• Pour one block at a mid range grade and measure height at four points along its length; record the spread.
• Weigh a cut sample from head, middle and tail of the block and confirm the density stays inside the grade band.
• Run the panel from its narrowest to its widest setting and confirm the drive locks at both ends.
• Check the belt speed against the panel readout at the lowest and the highest setting.
• Test both emergency halt switches and confirm the head wash cycle completes.
• Confirm the cut off station follows belt speed while the run continues.

Documentation and Compliance Pack

Every set ships with foundation and installation drawings, a wiring diagram, the trial block report with the working values, an operation manual in English, a spare parts list with part numbers, and a CE declaration. The drawings are issued before shipment so the foundation can be poured while the line is in transit, and the trial block report is written on the day of commissioning so the plant has a reference for its first month of production.

Spares Policy and Service Response

Warranty runs 12 months from commissioning, with lifetime spare parts support after that. We keep mixing head seal kits, dosing pump diaphragms and temperature probes in stock, and we recommend two seal kits and one diaphragm set on the plant shelf from day one, because those are the parts that decide if a line is down for an hour or for a week. Process questions during start up are handled remotely against the trial block report, and site support can be arranged when a grade needs work on the panel setting.

Shipping and Commercial Terms

The line loads into two 40 ft containers. Head, cabinet and pumps travel in wooden cases; frame sections are bundled by section and wrapped in plastic film. Delivery is about 45 working days after the down payment, with T/T or L/C at sight. Loading photographs and the packing list are issued before the containers leave Qingdao.

Questions From Plant Engineers

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