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 replace its fully manual setup with a semi-automatic batch foam machine.
Production Issues That Also Needed Adjustment
During communication, the customer also raised two quality issues in conventional foam production:
- Core scorching in low-density foam
- Visible small holes in foam used for footwear
Technical Adjustment Before Final Equipment Matching
Before the final equipment configuration was confirmed, our foaming engineers provided remote technical guidance based on the customer's existing production conditions. The support covered formula and process adjustments, raw material selection, and equipment recommendations.
For core scorching in low-density foam, we adjusted the water content and other aspects of the formulation. For the visible small holes in foam used for footwear, keeping the raw materials at around 20°C helped reduce the occurrence of these defects in the customer's production.
Both issues had already improved through this technical support before the customer placed the equipment order.
Our team carried out installation at the customer's factory. During the on-site support, our foaming engineer trained the customer's team in:
- Machine operation
- Batch foam production
- Process adjustment 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
The semi-automatic batch foam machine was the main equipment in this upgrade. Small additives still required manual weighing and addition, while the main operating steps were controlled through the PLC system.
Compared with the customer's original fully manual setup, this made daily operation easier to control and reduced dependence on individual operator experience.
Foam Top Flattening and Mold Size Adjustment
The mold could be adjusted for different foam block dimensions, reducing the need for separate molds in multiple sizes.
Project Result
The technical adjustments resolved core scorching in the customer's low-density foam and reduced the occurrence of visible small holes in its footwear foam.
The equipment upgrade reduced material waste, improved production efficiency, and made operation more stable, with less dependence on individual operator experience.
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: Foshan City, Guangdong Province China