Flexible PU Foam Block Box Foaming Solution Banner background

Flexible PU Foam Block Box Foaming Solution

Semi-automatic batch production of flexible polyurethane foam blocks, integrating material preparation, barrel mixing, free rise, conditioning and cutting.

8–80kg/m³ Specified Density Range
60kg Approx. Maximum Pour Weight
2 Standard Square Molds
Discuss a Box Foaming Project
Flexible Polyurethane Foam

Batch Box Foaming for Flexible PU Blocks

Haifeng configures a batch Box Foaming route for flexible polyurethane blocks used in furniture padding and related foam products. The selected semi-automatic route prepares PPG, POP and TDI, weighs minor ingredients, mixes in a tilting barrel and pours into individual box molds. Free rise, conditioning and cutting are separate stages, with formulation and production trials defining the operating conditions.

Box Foaming Production Workflow

Separate mixing and pouring from foam rise, conditioning and cutting.

01

Prepare Materials

Condition main raw materials and weigh silicone, catalysts, water and pigments according to the recipe.

02

Mix and Pour

Pump the main materials into the mixing barrel, add weighed minor ingredients, mix and pour into the selected mold.

03

Free Rise and Condition

Allow the foam to rise, then demold and condition the block before downstream cutting.

Selected Configuration and Equipment Gallery

Semi-automatic batch configuration and illustrated equipment options.

Semi-Automatic Batch Box Foaming Configuration

This route meters main raw materials into a mixing barrel, manually adds weighed minor ingredients, mixes at high speed and pours into individual molds. Foam rises freely, then is demolded, conditioned and cut. The configuration below describes the semi-automatic barrel-mixing route from the supplied technical brief.

Parameter / ModuleSelected Semi-Automatic ConfigurationScope / Selection Notes
Material systemPPG, TDI, POP; silicone surfactant, A33, T9, water and pigment additivesMain materials are pump-fed; minor additives are manually weighed for the recipe.
Foam density8–80 kg/m³Configuration range; confirm formulation and block quality through trials.
Standard square mold1,050 × 1,050 × 1,200 mm; two setsCircular and other molds in the gallery are reference options, not the included square-mold specification.
Maximum single pourApprox. 60 kgPour weight; not an output flow in kg/min.
Metering accuracy±0.5% as stated for the metering systemMain-material metering; manually added minor ingredients require separate weighing control.
Mixing barrel560 mm diameter; pneumatic tiltingHigh-speed batch mixing followed by pouring into the box mold.
Mixing motor / maximum speed11 kW / up to 6,000 r/minSelected semi-automatic configuration; other reference machines differ.
Main material tanksPPG 3 t / TDI 3 t / POP 3 t as specifiedMass-capacity notation; no conversion to m³ without material density.
Machine envelopeApprox. 3,500 × 2,500 × 2,800 mmIncludes the three main tanks in the supplied configuration description.
Temperature conditioningTank coils with heating/cooling water circulation; stated control range 20–50°CThe described preconditioning step uses 20–40°C, adjusted to the formulation.
ControlsMitsubishi PLC, Delta 10-inch HMI and inverterFinal brands, models and valve selection follow the agreed equipment schedule.
Main machine power52 kW statedComplete-line utility load to be confirmed because source totals differ.
Horizontal rotary cutter1,500 × 2,000 mm cutting area; 1,200 mm cutting height; 2–150 mm thickness8.92 kW motor; 10,000 mm blade; table speed 0–3.5 r/min; thickness control.
Vertical cutterInner table 1,720 × 2,440 mm; outer table 2,000 × 2,440 mm1,200 mm cutting height; 600 mm fence; 8,900 mm blade; 1.74 kW motor; spare blade and grinding wheel.
Workspace / staffingRecommended workshop ≥20 × 10 m; 2–3 trained operatorsAllow raw-material storage, box handling, ventilation, curing and cutting access.
Electrical supplyThree-phase 380 V ±5%, 50 Hz; reliable groundingFinal load schedule includes the selected compressor, chiller, cutting machines and auxiliaries.
Compressed air0.6–0.8 MPa; dry, oil-free air; ≥1.5 m³/minFor pneumatic tilting and valves; confirm compressor sizing.
Cooling water≤25°C; circulation flow ≥3 m³/hCoordinate with the selected heat-exchange and chiller equipment.
Ambient conditions15–35°C; relative humidity ≤80%; no condensationProvide a ventilated hardened floor and suitable material-storage area.
Curing and cuttingDocumented free-rise/demolding interval approx. 20–40 min; conditioning ≥24 hRecipe-dependent references; confirm safe demolding and cutting readiness through trials, separate from mixing/pouring time.

Equipment and Supply Interfaces

The proposed package includes the mixing unit with three main tanks and controls, two square molds, horizontal and vertical cutting equipment and routine spares. Material feeding automation, a chiller, material heating and nitrogen-supply interfaces are configured to the project. Confirm the equipment schedule, layout, utility demand, service terms and delivery plan before ordering.

Production Planning

Batch output depends on formulation, block density, rise time, box changeover, curing space and cutting capacity. The supplied brief lists example pour weights of approximately 16 kg at 12 kg/m³, 33 kg at 25 kg/m³ and 59 kg at 45 kg/m³ for the stated square mold. These are planning examples rather than measured customer outcomes or guaranteed shift production.

The supplied values describe this barrel-mixing configuration. Single-pour mass, metering flow, rise/demolding, conditioning and cutting are separate; production capacity follows trials and the agreed schedule.

Related Box Foaming and Cutting Equipment

Product 872 is a related low-pressure machine family; product 1779 is related cutting equipment. Neither link establishes the complete tilting-barrel package. Confirm the actual equipment schedule and material/mold interfaces.

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Low-Pressure Box Foaming Machine | Foam Blocks

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PU Foam Cutting and Slicing Equipment | Foam Blocks

Haifeng supplies PU foam cutting equipment for slabstock blocks, with synchronized cut-off and configurable slicing or CNC contour modules for furniture padding.

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Automatic Box Foaming Machine | Flexible PU Foam

Automatic box foaming equipment for batch production of flexible polyurethane foam. The supplied configuration includes raw-material mixing, foam forming and a touchscreen control system for managing formulations, with automatic and manual operating modes. Foam blocks are produced in individual molds and then transferred to the agreed conditioning and downstream cutting stages.

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Manual Vertical Foam Mixing Machine | Batch Flexible PU Foam

Mixes manually charged flexible PU foam raw materials in a bucket using timed high- and low-speed mixing. The mixed charge is poured into a separate mold for foaming.

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Manual Base Mounted Foam Mixing Machine | Batch Flexible PU Foam

Mixes manually charged flexible PU foam raw materials using timed high- and low-speed mixing in a base-mounted bucket arrangement. The mixed charge is poured into a separate foaming mold.

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Horizontal Foam Block Slicer | Flexible Foam Sheets

Slices foam blocks into sheets using digital thickness settings and a reciprocating worktable. Pressure rollers help retain the foam; a vacuum arrangement is optional.

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Automatic Vertical Foam Cutter | Foam Block Conversion

Cuts foam vertically with touchscreen and PLC settings for multiple thicknesses. A fixed aluminum worktable holds foam between retaining plates while the blade carriage travels on linear guides.

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Foam Roll Compression Packaging Machine | Flexible Foam Roll Packaging

Compresses foam rolls while wrapping them in packaging film, followed by sealing and cutting. The described arrangement includes automatic loading and unloading.

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Box Foaming Selection Questions

What is Box Foaming? +
Box Foaming produces separate polyurethane blocks by pouring a reactive mixture into individual molds for free rise. Blocks are demolded, cured and conditioned before cutting or slicing.
Are all ingredients automatically metered? +
In this semi-automatic configuration, PPG, POP and TDI are pump-fed, while minor additives are weighed and added manually according to the recipe. Automated minor-component metering requires a different equipment scope.
What mold shapes are available? +
The selected package specifies two square molds of 1,050 × 1,050 × 1,200 mm. The circular mold image illustrates an alternative mold arrangement; its size and supply scope need separate confirmation.
Does the 60 kg value describe output per minute? +
No. Approximately 60 kg is the maximum single-pour weight stated for this configuration. Pour flow and mixing time are separate settings.
When can blocks be cut? +
The brief lists an approximately 20–40 minute free-rise/demolding stage and at least 24 hours of subsequent conditioning. Confirm demolding and cutting readiness for the formulation and block size through production trials.
How is the electrical load selected? +
The main-machine specification lists 52 kW. Complete-line demand depends on cutting, temperature control and compressed-air equipment; obtain an agreed load schedule before sizing the factory supply.
How does Box Foaming differ from Continuous Slabstock Foaming? +
Box Foaming uses individual batch molds and separate pour cycles. Continuous Slabstock Foaming feeds the reaction mixture onto a moving forming conveyor for continuous bun production and synchronized cut-off. Choose according to the formulation, capacity, changeover needs and available space.
Does the linked low-pressure machine represent the complete batch package? +
The low-pressure machine is a related family reference. The selected semi-automatic route uses a tilting mixing barrel and separately listed tanks, molds and cutting equipment. Confirm the exact supply list rather than treating the related machine as the full package.

Discuss Your Box Foaming Configuration

Share formulation, density, mold dimensions, batch mass, box count, full batch sequence, daily working hours, conditioning space and cutting demand to define the actual package.

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