Continuous PU Foam Block Making Machine 45 Meter Tunnel Output 2000-7000mm Per Minute

This continuous PU foam block making machine is engineered for factories that produce flexible polyurethane slabstock around the clock. A 45 metre foaming tunnel carries the reaction mixture on a moving conveyor at 2000 to 7000 millimetres per minute, so a single line delivers a steady stream of blocks instead of batch by batch output. The pour carriage travels across the full 2200 millimetre block width while the fall plate follows the rising foam crown, keeping the top surface flat and the side skins square. Because every parameter is held by servo drives and a closed loop controller, the density profile stays inside a tight window from the first metre to the end of the run. The machine accepts TDI and MDI formulations, polyester and polyether polyols, and can be fitted with additional metering streams for colour paste, flame retardants and catalysts. The steel frame is welded and stress relieved before machining, so the conveyor rails remain parallel after years of continuous operation. Daily maintenance is limited to filter cleaning, seal inspection and a short lubrication round, which keeps unplanned downtime low in high volume plants.

• Continuous Tunnel Pouring: The 45 metre tunnel and servo driven conveyor keep foam rising at a constant rate, so blocks are cut with a repeatable density from head to tail and waste at the ends is reduced.
• Wide Speed Window: Conveyor speed is adjustable from 2000 to 7000 millimetres per minute, letting one machine run light grades and heavy grades without mechanical changes.
• Flat Top Control: A motorised fall plate and side wall film system hold the foam crown flat, which cuts trimming losses and improves the yield of every block.
• Multi Stream Metering: Up to eight metering streams handle polyol, isocyanate, water, silicone, catalyst and colour paste, so new formulations can be introduced without extra hardware.
• Rigid Welded Frame: The main frame is welded, stress relieved and machined in one setup, keeping the conveyor rails aligned and the block geometry stable over long production campaigns.
• Recipe Storage: The PLC stores up to 100 recipes and recalls every pump speed and conveyor value in seconds, shortening changeover between product grades in daily production.

Continuous lines of this type serve mattress and upholstery foam plants, furniture factories and converter workshops that need a constant supply of slabstock. The output feeds vertical and horizontal cutting machines, contour cutters and CNC routers, so the same block can become mattress cores, sofa seat cushions, packaging inserts or acoustic panels. Because the block height and width are adjustable, plants can shift between standard mattress grades and thick furniture grades within one shift, which helps when a customer mix changes quickly.

Each machine is wrapped in protective film, packed in fumigated plywood cases and loaded in 40HQ containers with reinforced steel brackets. The package includes a full set of spare seals, filter elements and a tool kit. A twelve month warranty covers the main frame, motors and control system, and engineers can travel to site for installation, commissioning and operator training. Remote support over video and a shared control log help the customer team solve minor faults without waiting for a service visit, and spare parts are kept in stock for fast dispatch.