PU Block Foaming Production Line with 930-2300mm Adjustable Panel

• 130 kW single electrical package: dosing, mixing, panel drives, conveyor and temperature channels run from one cabinet, so a fault is traced at one station instead of across the line.
• 30000 kg frame: the mass holds the line steady through a run, which keeps the block square and the panel alignment stable over a full shift.
• One operator at the panel: the cycle runs from the control station with a forklift at the discharge side, which is a lower labour cost per tonne than a batch foaming station.
• 18 m oven rack and 25 m conveyor: the block cures through before the cut off, so the cut face is square and the cutting line does not reject the first metres.
• 930 to 2300 mm adjustable panels: the block width is changed on the panel drive between runs, which lets one line supply two product families.
• Recipe repeatability: head pressure, conveyor speed and block height are recorded every 30 minutes, so a run can be repeated from the record rather than from memory.

• Mixing head: 37 kW drive with a metered dosing block, so the isocyanate and polyol ratio holds through a long run and the block density stays inside the recipe.
• Side panels: adjustable from 930 mm to 2300 mm, with a rising section that follows the foam as it expands to the set height.
• Oven rack: 18 m of falling plate and side wall, which holds the block square while it cures and reduces the trimming needed downstream.
• Conveyor: 25 m of belt running at 2–6.5 m/min, matched to the recipe so the block is cut only after it has cured through.
• Control cabinet: one panel with dosing, conveyor and temperature readouts, so a recipe change is made at one station.

• Mattress manufacturing: block foam for cores and overlays, produced to the density the cutting line and the cover are built for.
• Furniture and upholstery: block stock for seat, back and armrest foam, with the block width matched to the cutting plan.
• Automotive interiors: seat padding and trim foam grades produced in a continuous run with a stable density.
• Footwear and apparel: soft foam for insoles, bra padding and garment interlining, where density controls the hand feel.
• Packaging and electronics: cushion foam block for export packing, produced to the thickness the packing line needs.
• Industrial and construction foam: semi rigid and rigid grades for insulation, sealing and gasket stock.

1. Confirm the recipe with the density and the hardness target, then set the dosing pumps and the mixing head speed on the panel.
2. Set the side panel width and the foaming height to the block size for that recipe, and lock the panel position before the run starts.
3. Set the conveyor speed within 2–6.5 m/min so that the block cures through before the cut off station.
4. Start the dosing, confirm the flow at the mixing head, and let the first 3 m of block establish before the panel section closes.
5. Record the head pressure, the conveyor speed and the block height every 30 minutes, so a drift can be traced to a parameter.
6. Cut the block at the length the cutting plan needs, then move it to the curing bay with the forklift and stack it flat.

• Take the 18 m oven rack when the plant runs furniture and mattress grades where a square block reduces trimming loss.
• Take the 25 m conveyor when the curing room is short, since the longer conveyor gives the block more time before the cut off.
• Order the 2300 mm panel when the cutting plan needs wide mattress block, and the narrow panel version for furniture block.
• Plan 110 kW of installed load and a 100 mm foundation, since a 30000 kg line needs a rigid floor and a dedicated feeder.

The line is installed on a concrete foundation with an embedded steel channel, because a 36000 mm frame will take a set if the floor moves under it. The mixing head, the panel section and the conveyor are aligned to a common centre line within 2 mm, and the oven rack is levelled along its full length before the panels are set.

Commissioning runs a trial block at the lowest density in the range, then at a furniture grade and at a high density grade, with the density, the block height and the conveyor speed recorded for each. The dosing ratio is tuned on the trial block, and the recipe sheet is handed over with the trial results so the plant can repeat the run.

• The mixing head and the panel drives are interlocked, so the head cannot run with a guard open.
• Isocyanate and polyol lines are labelled and drained before any service, with the specified protective equipment in use.
• The emergency halt switch sits at the dosing station and at the cut off station, and both are tested at the start of each shift.
• The conveyor and panel area is fenced, and the line is walked only with the drive in local mode.
• Foam block is moved by forklift from the discharge side, with the driver in sight of the spotter.

Each line is pressure tested on the dosing circuit, run on a trial block and checked for density at three points along the block before dispatch. The panel alignment, the oven rack level and the conveyor tracking are recorded on the test sheet, alongside the mixing head current at duty load. The serial number is stamped on the head frame and on the control cabinet so a spare seal or a pump diaphragm can be matched to the build, and a CE declaration travels with the set.

The mixing head, the control cabinet and the dosing pumps travel in wooden cases, and the panel section, the oven rack and the conveyor frame are nude packed with plastic film and bundled by section. The line loads into two 40 ft containers. Delivery is about 45 working days after the down payment, and the installation drawings are sent before shipment so the foundation can be prepared in parallel.