Flexible Foam Production Line

Foam Batch Production line

Minimum space required, quick start-up, flexible production Machines of this type have a track record of over years in Dis continuous slab stock production. When it comes to manufacturing rectangular and round blocks users exert maximum influence on the quality and property of the foam, thus producing the high-grade basis of a great number of end products such as mattresses or upholstered furniture. On top of this, the type series stands out for its compact machine layout and attractive pricing.

Range of application

The current generation offers even more options and allows a wide range of polyether-based products to be made:

• Standard foams

• High-resilient cold-curing foams (HR foam)

• Hyper soft foams (HS foam)

• High-load bearing foams (HL foam)

• Viscoelastic foams

• Spongy type of foams

Standard foams have a density of 20 to 50 kg/m³. The density can however be reduced down to 10 kg/m³ by adding suitable blowing agents. An extra metering line for blowing agent is available as an option.

Features

Machines rely on decades of know-how and well-proven quality components. This functional interaction ensures maximum production flexibility and top-quality results:

Four metering lines in the standard version ( Polyol , Isocyanate, Activator Mix And Stannous Octoate), which make production more flexible and minimize the time needed for preparing the raw material

Additional metering lines allowing a wide range of foam grades are also optionally available

(different polyols, isocyanates, additives) High-precision pumps to ensure accurate meteringand reproducibility of the formulation Homogeneous mixing and controlled influence on the

foam cell structure due to freely selectable mixer speed Precise addition of small amounts of stannous octoate

through the recirculation of the catalyst metering line Automatic cleaning of the mixing cylinder to ensure

continuous production

Machine control system

The operator uses a operator panel to control the machine.

The operating device allows an easy intuitive operation in several

languages. Up to 50 formulations can be stored and managed in the

PLC. At the touch of a button, a different formulation can be selected

from block to block.

Density range of foams without blowing agent [kg/m3] 20 - 50

Density range of foams with blowing agent [kg/m3] < 20

Maximum shot weight [kg] 150

Stirrer speed range [min-1] 300 - 950

Polyol tank capacity [L] 500*

Isocyanate tank capactity [L] 500*

Activator tank capacity [L] 100

Catalyst tank capacity [L] 40*

Size of a standard rectangular mould carriage L x B x H [m] 2,1 x 2,1 x 1,5*

Size of a cylindric mould carriage ø x H [m] 1,5 x 2,2**

Production capacty: Number of blocks made in an 8-hour shift St. /pces ~80

Number of operating staff [kg/m3] 3

Density range of foams without blowing agent [kg/m3] 20 - 50

Flexible Foam Batch Production Line

We developed and produced high-quality plants for polyurethane processing. It is considered the market leader in the field of slab stock machinery and equipment. This know-how is reflected in the systems. The latest generation of one of the world's most renowned slab stock lines impresses processors with its attractive price-performance ratio, which – thanks to a highly efficient raw material yield, outstanding foam qualities and the state-of-the-art system control – ensures a fast return on investment. Based on analyses and statements by leading slab stock foam producers and raw material manufacturers, the use of high-pressure technology saves up to 5 percent iso cyanate compared to low-pressure slab stock machines.

A further considerable cost saving results from the use of the proven LIQUID-LAYDOWN system together with rectangular process (FLAT-TOP system). 4-sided paper covering over the produced foam block – where the top rind is converted into usable foam – allows slab stock foam producers to achieve up to 5 percent higher foam yields compared to production without cover paper. And not forgetting: physical properties in terms of hardness and bulk density distribution are significantly optimized. This ensures the user a highly efficient raw material yield and the best foam quality. What is more, production can be further optimized by automating the Systems

FEATURES

lines are equipped with high-quality standard

components. High-quality and robust system components are part and parcel of plants. Especially in the field of

metering technology in particular, has significant

know-how and a high proportion of in-house production of all

relevant components. For users, this translates into increased

plant availability and lower maintenance and spare parts costs.

THE BASIS FOR HIGH-GRADE FOAM:

The Dynamic Msl Stirrer Mixer

One key factor that ensures high-quality and efficient

processing of polyurethane is mixhead technology. We have outstanding expertise in this area and makes its mixheads (apart from a few standard parts) in its own manufacturing halls. This guarantees the highest quality and performance. The height-adjustable mixer unit of the is the heart of the system. This powerhouse combines injection and stirrer principles with precise laminar liquid distribution through our calibration unit. The result? Exceptional foam quality — virtually void-free, striation-free, and with a uniform cell structure.

ADVANCED CELL CONTROL

HIGH PRESSURE ISOCYANATE INJECTION

A micro-fine spray effect in the mixing chamber leads to a significantly improved chemical reaction and bet­ter control over the cell size. In addition, isocyanate consumption is reduced by up to 5 %.

SPOUT-EX (OPTIONAL)

Effective extension for MSL agitator heads, which

is based on extensive flow simulations and

enables a significant reduction in pinholes,

especially with fine-cell foams

MOTORIZED THROTTLE

Targeted adjustment of the mixing chamber pressure to influence the cell size in a controlled manner

THE RANGE OF APPLICATION

Depending on the plant configuration, the series can be used to produce a wide variety of polyether-based slab stock foams with uniform hardness and density distribution. Besides the commercial foam types for the upholstery and mattress industry, slab stock is ideally suitable for technical items and for cutting into sheeting of any desired thickness. technology, utilizing the blowing agent CO2 makes it possible

to manufacture foams with low densities of up to 14 kg/m3.

This process does not only ful fill qualitative and economic criteria, it also meets ecological requirements because CFC or methylene emissions are avoided.

HIGH PRECISION AND RELIABILITY:

HIGH-PRESSURE METERING SYSTEM

The uses precision high-pressure pumps with large adjustment ranges to produce high-grade slab stock. All metering lines are equipped with recirculation systems for preliminary

adjustments and formulation changes. Exactly reproducible

metering outputs of the pumps and computer-controlled volume flow measurement ensure additional production stability.

The number of metering units and the metering outputs in

the standard configuration can be extended and adjusted at

any time to suit individual requirements

EVERYTHING IN SIGHT: AUTOMATED PROCESS CONTROL

is specially tailored to requirements of slab stock foamer. We have enhanced the proven functions of the previous generation PDE with a number of new features. Even in the standard version, the includes visualized flow charts, process charts and calibration history, as well as further software tools

for analyzing the actual and set point values. The "magic eye" function also makes it easier to identify any

irregularities by displaying the pressure data in a graph.

Nothing now stands in the way of perfect production results.

At the customer's request, the plant can be equipped with

additional functions, such as sensors that visualize current

information on the rise curve of the slab stock foam produced and enables a real-time comparison of the gradient profile with

defined reference curves.

SYSTEM ADVANTAGES

Highly efficient raw material yield

and cost savings through:

high-pressure technology for all components

• 4-page paper system (including FLAT-TOP-System)

• Recirculation for all metering lines

• Availability of additional functions such as tilting

side walls and pneumatic nozzles for all metering lines

High foam quality and cell control

• Application of high-pressure technology also for additives

• Height-adjustable mixer with direct

LIQUID-LAYDOWN output

• Uniform hardness and density distribution

Manufacture of low-density foams

thanks to the technology

Modular design to ensure a cost-effective operation

and an optimum adaptation to market requirements

User-friendly and easy handling thanks to highly modern

and intuitive process control system

Flexible Foam Continuous Production Line