Twin-Nozzle Flexible PU Foam Making Machine Dual Color Block Production Two Component Head

Two colour and dual density foam blocks sell at a premium in the mattress and furniture market, and this twin-nozzle flexible PU foam making machine produces them on a single continuous line. Two independent mixing heads, each fed by its own dosing group, travel on the same carriage and can pour side by side, in alternating bands or in a layered pattern controlled by the PLC. Colour change between blocks is handled by a purge sequence and a short solvent flush, so downtime stays near ten minutes even when moving from a dark colour to a light one. Each head has its own recipe channel, which means the two streams can carry different catalyst packages and cure at compatible rates, avoiding the interfacial separation that ruins a dual density block. The control system monitors both streams and stops the pour if either ratio drifts outside the alarm window, protecting the material that has already been poured. The carriage rails are extended to give the heads room to cross over, and the film system is duplicated so both sides of the block stay clean.

• Two Independent Heads: Each mixing head has its own dosing group and recipe channel, so the two streams can differ in colour, density or catalyst package within one block.
• Pattern Programming: Side by side, banded and layered patterns are stored in the PLC, letting the plant sell distinctive visual blocks without manual head handling.
• Fast Colour Change: A programmed purge and solvent flush sequence brings colour change downtime to about ten minutes, protecting output on short custom runs.
• Compatible Cure Rates: Separate catalyst channels let both streams reach a compatible cure, preventing interfacial separation and rejects in dual density blocks.
• Ratio Guard: Both streams are monitored against an alarm window and the pour stops automatically if either drifts, protecting material already in the tunnel.
• Duplicated Film System: Both sides of the block are filmed independently, keeping skins clean when two colours meet at the block face.

Mattress brands use dual colour blocks for visual differentiation in retail displays, while furniture makers use dual density blocks to combine a soft comfort layer with a firmer support base in one piece. Technical foam producers use the same capability to combine a conductive or flame retardant layer with a standard core. Because both streams are independent, a plant can also run single colour production on one head while the second head is under maintenance, which keeps output flowing during service work.

Both heads are shipped in foam lined cases and the carriage is braced to prevent rail movement in transit. The package includes a colour purge kit, spare nozzles for both heads and a pattern programming guide. The warranty is twelve months on heads, pumps and controls with twenty four months on the frame. Commissioning includes training on pattern setup and colour change procedure, and the technical team reviews the first dual density block samples to confirm that the interface between the two streams cures without separation.