High-Pressure PU Foaming Machine | Flexible and Integral Skin Foam
Two-component high-pressure PU metering for flexible and integral-skin foam, with closed-loop flow monitoring, temperature conditioning and a self-cleaning impingement mixing head.
100–650 g/s
Reference combined output at POL:ISO = 2:1
6–20 MPa
Specified injection-pressure range
2 × 250 L
Independent jacketed component tanks
Metering, Mixing and Process Coordination
Two-component high-pressure PU metering for flexible and integral-skin foam, with closed-loop flow monitoring, temperature conditioning and a self-cleaning impingement mixing head.
This two-component high-pressure polyurethane metering configuration processes flexible and integral-skin foam systems. Separate polyol and isocyanate circuits feed a hydraulically operated, self-cleaning impingement mixing head. Component flow monitoring and variable-speed pump control coordinate dosing with the selected recipe and workstation.
The JHF60 configuration specifies a combined output of 100–650 g/s at a polyol-to-isocyanate ratio of 2:1 and an injection-pressure range of 6–20 MPa. Output at other ratios and material viscosities requires separate sizing and calibration. Final foam properties depend on the formulation, mold and processing conditions.
The equipment package includes two jacketed 250 L material tanks, independent heat exchangers, metering units, automatic refill equipment, circulation changeover valves, a hydraulic power unit and a PLC/HMI control system. The mixing head is supported by an adjustable-height rotating jib for multiple injection positions.
Installation and Commissioning Preparation
Confirm the layout and jib operating envelope before positioning the machine. Review electrical, water and compressed-air connections against the approved utility schedule. Define who supplies the trial raw materials, molds, release agents and commissioning consumables, and arrange lifting access and operator participation before startup. Final installation, training and service responsibilities follow the project agreement.
Production Workflow
Condition the materials
Set the component temperatures and establish material circulation.
Select and verify the recipe
Check component discharge, flow feedback, ratio and shot settings.
Inject and clean the head
Coordinate impingement mixing, timed injection and mechanical cleanout with the mold cycle.
Technical Configuration
| Technical Parameter | JHF60 |
|---|---|
| Components | 2 components: polyol and isocyanate |
| Output Range (g/s) | 100–650 g/s, combined output at POL:ISO = 2:1 |
| Mixing Ratio Range | Output reference at 2:1; final adjustable ratio envelope requires confirmation |
| Ratio Accuracy | Mix-ratio accuracy is not specified; confirm by component discharge calibration |
| Power Supply | 380 V, three-phase, five-wire supply; supply frequency to be confirmed |
| Working Pressure | 6–20 MPa injection pressure |
| Tank Capacity (L) | 2 × 250 L effective material-tank capacity |
| Dimensions (L×W×H) | 2000 × 4500 mm reference footprint; height and jib clearance to be confirmed |
| Compatible foam systems | Flexible polyurethane foam and integral-skin polyurethane foam |
| Shot repeatability | Specified ≤±1%; test conditions to be agreed |
| Closed-loop component flow accuracy | Specified flow error ≤±1%; test conditions to be agreed |
| Injection time | 0.5–99.99 s; 0.01 s setting resolution |
| Material temperature | 20–30°C setting range; temperature-control deviation ±2°C |
| POL metering unit | JZB28 pump; maximum stated pump displacement 40 L/min; 11 kW motor |
| ISO metering unit | JZB12 pump; maximum stated pump displacement 17 L/min; 5.5 kW motor |
| Mixing head | JHV1218-2K; hydraulically actuated, self-cleaning impingement design |
| Flow monitoring | POL VC3 and ISO VC1 flowmeters; component feedback to variable-speed pump control |
| Material conditioning | 2 × 6 kW heating units; stated cooling capacity 20,000 kcal/h |
| Heat exchangers | Two stainless-steel heat exchangers, 5 m² each, in the component return circuits |
| Hydraulic unit | 20 L/min; 10–20 MPa hydraulic-system pressure; 100 L reservoir and 10 L accumulator |
| Compressed air | Dry, oil-free air; reference 0.6 MPa and 400 NL/min |
| Filtration | 0.2 mm component line filters; additional 0.1 mm high-pressure ISO outlet filter |
| Control hardware | Siemens S1200-series PLC and TP900 operator panel in the supplied reference |
| Recipe programs | 32 standard injection programs, expandable; workstation-specific program selection |
| Automatic refill protection | Low-level refill request, extreme-low pump stop, high-level refill stop and overflow alarm |
| Total installed power | 45 kW |
| Site interfaces | Compressed-air interface G1/2; softened temperature-control water interface G3/4; hose routes from approved plant layout |
Equipment and Control Functions
Closed-Loop Component Flow Monitoring
Flowmeters provide component feedback to the variable-speed metering pumps. Flow deviations generate an alarm and inhibit the next injection.
Self-Cleaning Impingement Mixing
The hydraulically operated head mixes the two streams by impingement and uses a mechanical cleanout cycle.
Independent Material Conditioning
Jacketed tanks and separate return-line heat exchangers maintain the component temperatures required by the selected material system.
Level and Pressure Protection
Automatic refill and limit alarms coordinate pump operation, refill stops and component-pressure monitoring.
Recipe and Production Records
The stated control package records injection quantities, ratios, pressure trends, component temperatures, alarm history and shift counts.
Workstation and Service Interfaces
The control package supports workstation-specific recipes and configurable remote diagnostics interfaces; implementation and access are defined in the final project scope.
