Guinea Furniture Manufacturer Rebonded Foam Project

The customer, based in Guinea, is a large furniture manufacturer with many years of manufacturing experience. The customer's original furniture business mainly focused on metal furniture, while the upholstered furniture business was only just getting started. Before this project, the customer had no experience in either foam production or rebonded foam production. 

The project was launched to process PU foam offcuts from the customer's own factory and produce rebonded foam for its upholstered furniture. By August 18, 2026, successful production trials had been completed and the equipment had entered regular use.

Project Background

Although the customer was new to rebonded foam production, its standards for the equipment itself were quite high. Many of the machines the customer had previously used or evaluated were from Europe, as well as from some major Chinese brands. As a result, the customer had relatively high expectations regarding equipment performance, appearance, workmanship, material quality, structure, and detail finishing.

What the Customer Focused on Most Before Purchasing

Before confirming the solution, the customer's concerns were quite clear and mainly centered on the following aspects.

Technical Support and Start-Up Guidance

With no previous experience in rebonded foam production, the customer's main concern was whether we could provide on-site process setup and practical training to help its team start production and operate the equipment independently.

Machine Durability and Build Quality

The customer paid close attention to the machine's materials, structural design, workmanship, and finish when assessing its build quality and durability.

Reliable Delivery Arrangements

The customer also paid attention to whether the delivery schedule was reliable and whether the equipment and related supporting items could be advanced according to the agreed timetable.

Why the Customer Ultimately Chose Us

The customer ultimately chose Sabtech based on its assessment of our communication, equipment, and proposed production support. The main reasons were as follows.

Timely Replies and Higher Communication Efficiency

We responded promptly to the customer's questions about the equipment, technical support, and delivery arrangements throughout the purchasing discussions.

The Equipment Itself Inspired More Confidence

We used comparison photos to explain the machine's materials, construction, and workmanship, addressing the customer's concerns about build quality and durability.

The Solution Was Better Aligned with the Customer's Actual Operating Conditions

The customer needed an operating process that a team new to rebonded foam production could follow. As its foam offcuts came mainly from its own factory and the material mix varied relatively little, production settings could be established for repeated use.

The machine can store and recall foam scrap weight, mixing time, and forward and reverse mixing settings. The programmed mixing sequence then runs automatically, reducing the need for operators to time each stage and switch direction manually.

This reduces the risk of missed direction changes or excessive mixing time. On-site process setup and training were also included to establish suitable settings for the customer's materials and product requirements.

Corresponding Adjustments Were Made for the Customer's On-Site Conditions

We made the following equipment adjustments to suit the customer's operating conditions:

• Fitting a guard at the binder pouring opening to prevent foam particles from scattering out during mixing
• Enlarging and reinforcing the working platforms to accommodate the operators’ larger body size and weight
• Adding emergency stop controls in clearly visible positions

The Equipment and Key Supporting Materials Could Be Supplied Together

Alongside the equipment, we supplied PU binder for rebonded foam production and spray adhesive for bonding foam pieces in the customer's furniture manufacturing. Sourcing these items together reduced the customer's need to coordinate separate suppliers for equipment and adhesives.

Procurement Scope

The items finally confirmed by the customer included:

Equipment

• 1 set of Rebonded Foam Machine
• 1 set of Foam Crusher

Supporting Materials

• PU binder for rebonded foam production
• Spray adhesive for foam bonding in furniture manufacturing

Equipment Capacity

Based on the confirmed configuration, under an 8-hour working schedule, the full set of equipment is capable of producing about 20 foam blocks per day, which is sufficient to fully handle the amount of foam scrap the customer currently generates each day.

Container Loading and Shipment

The equipment and supporting materials for this project were loaded and shipped on March 28, 2026. During container loading, we optimized container space utilization to reduce transportation costs.

After delivery, a Sabtech engineer visited the customer's factory to set up the rebonded foam process and train the operators. Based on the available foam scrap and the customer's density and firmness requirements, the engineer recommended a material blend and established the scrap weight per block, total mixing time, and forward and reverse mixing durations.

These settings were saved in the machine for subsequent production. Training covered incoming material screening, shredding precautions, and operating steps that required particular attention. The engineer also provided material-use recommendations to help control costs based on the customer's available scrap.

Production Results

By August 18, 2026, the project had completed successful production trials and entered regular production. The rebonded foam met the customer's density and firmness requirements and was being used in its upholstered furniture. Following on-site training, the customer's team could operate the equipment and carry out production independently.

If you are also evaluating a rebonded foam machine solution, or considering how to build rebonded foam production capability using your own in-house PU foam scrap, you are welcome to send us your raw material conditions, target applications, and site conditions. Based on experience from similar projects, we can help you further clarify the configuration approach and supporting solution.