End-to-end solutions from raw materials to production equipments for PU foam and mattress-Sabtech
Indonesian Foam Factory Equipment Upgrade Case
Project Background
In May 2022, we received an inquiry from a foam factory in Indonesia. The factory produced both rebonded foam and conventional PU foam for the local market.
This project focused on upgrading the conventional foam production section, where the customer was still using a fully manual batch foaming setup.
Why the Upgrade Was Needed
The original production setup had several clear limitations in daily operation:
- Unstable process control
- High material waste
- Low production efficiency
- Strong dependence on operator experience
For a factory already in regular production, these issues directly affected output consistency and material utilization. The customer therefore planned to upgrade from a fully manual setup to a semi automatic batch foam machine process.
Production Issues That Also Needed Adjustment
During communication, two production problems in the conventional foam section also needed attention:
- Low-density foam was prone to inside-burn
- Foam produced for insoles tended to develop large pinholes
Technical Adjustment Before Final Equipment Matching
Before confirming the final equipment configuration, our foaming engineers worked around the customer’s existing production conditions and provided support in several areas:
- Formula adjustment
- Process setting adjustment
- Raw material matching advice
- Equipment matching suggestions
- Remote technical guidance
For the large pinholes in insole foam, the main adjustment focused on temperature control, based on the local environment, raw material condition, target density, and current equipment setup.
Equipment Ordered
In July 2022, the customer placed an order for the following equipment:
This equipment combination matched the customer’s plan to upgrade the conventional foam production section.
After the equipment order was confirmed, our team went to the customer’s factory for installation.
At the same time, our foaming engineer trained the customer on:
- How to operate the machine
- How to run batch foam production
- How to adjust the process based on actual production conditions
This support helped the customer connect the new equipment with actual production more smoothly.
Semi Automatic Batch Foam Machine Upgrade
In this project, the semi automatic batch foam machine was the key equipment in the upgrade.
Compared with the original fully manual production method:
- Small additives still needed to be weighed and added manually
- The main operating steps could be completed through the PLC system
- The overall workflow became clearer
- Daily operation became easier to control
- Dependence on individual operator experience was reduced
For factories moving from fully manual batch foaming toward a more controlled production process, this kind of upgrade helps turn a more experience-dependent operation into a more stable and easier-to-repeat workflow.
Configurations That Helped Reduce Waste
Two configuration points were especially practical in this project:
- Top-flat device
-Helped make the foam top flatter
-Reduced waste caused by the top crown
-Improved material utilization during production
- Adjustable box mold
-Allowed size adjustment for different foam dimensions
-Reduced the need to prepare multiple molds in different sizes
-Improved flexibility for different production requirements
Project Result
After the equipment upgrade and technical adjustment:
- The inside-burn problem in low-density foam was solved
- The large pinhole issue in insole foam was improved
- Material waste was reduced
- Production efficiency improved
- Operation became more stable
- Dependence on operator experience was lowered
For foam factories still facing high material waste, unstable operation, or strong dependence on manual experience, Sabtech can help review the current production setup and match a more suitable upgrade solution.
Just leave your email or phone number in the contact form so we can send you a free proposal!
Contact Person: Cynthia Cheung
Contact Number: +86-15687268672
Email: sales@alforu.cn
WhatsApp: +86-15687268672
Company Address: Dongguan City, Guangdong Province China