Libya Foam Factory Upgrade: 16-Component Continuous Foaming Line

A foam and mattress manufacturer in Libya upgraded its existing batch foaming system to a 16-component continuous foaming line. Sabtech also supplied the client with a vertical foam cutting machine, mattress materials, and foaming raw materials.

The production line officially entered operation in September 2024, achieving an actual output of approximately 500 cubic meters per day and exceeding the client’s expectations.

Project Background and Reasons for the Upgrade

The client manufactures both flexible PU foam and mattresses and previously used a batch foam machine for foam production. As production demand increased, the existing system gradually presented several problems:

• Foam density varied between batches.
• The foam structure lacked consistency.
• Production capacity was insufficient.
• The production process had a low level of automation.

The client therefore decided to replace the existing foaming equipment and upgrade from batch foaming to continuous production to improve production stability, capacity, and automation.

The Client’s Main Concern and Purchasing Decision

The client’s main concern was whether its team could master the operation and production control of a continuous foaming line. Continuous foaming requires coordination between raw material metering and delivery, mixing, foam rise, and conveyor speed, making its operating method different from that of a batch foam machine.

Before confirming the order, the client compared several suppliers, focusing on initial investment, equipment stability, automation level, and technical support.

Through remote meetings and video demonstrations, Sabtech introduced the equipment structure, operating method, and project support arrangements. The client then visited Sabtech’s factory in China for an on-site inspection and further discussions with the technical team.

Professional communication, timely responses, and ongoing technical support were important reasons why the client ultimately chose Sabtech.

Solution Provided by Sabtech

The client’s initial order included:

• One 16-component continuous foaming line
• One vertical foam cutting machine
• Mattress materials, including fabric and springs
• Foaming raw materials, including POP, PPG, silicone, an amine catalyst, and a T-9 catalyst

The continuous foaming line was intended to improve foam production stability, capacity, and automation. The vertical cutting machine supported subsequent foam cutting, while the foaming raw materials and mattress materials supported the client’s foam and mattress production.

Why a 16-Component Configuration Was Selected

The client did not initially specify a 16-component configuration. Sabtech proposed this solution based on the client’s daily output requirements, color requirements, and production cost-control needs.

The configuration was selected for three main reasons:

• To meet the client’s daily production requirements
• To provide greater flexibility for producing foam in different colors
• To help control production costs through the powder tank configuration

The 16-component configuration included:

• Nine base-material and additive components: PPG, powder, POP, TDI, methylene chloride, silicone oil, A33 amine catalyst, T-9 catalyst, and water
• Six color components: one black color tank and five additional color tanks
• One spare tank

Production Control Configuration

The production line uses a PLC control system, allowing operators to centrally set and manage production parameters and equipment operation through the control interface.

The line is also equipped with a foam height monitoring function, enabling operators to observe changes in foam height and monitor the foaming condition.

Installation, Commissioning, and Training

Project discussions began in October 2023. The main implementation stages were:

• October 2023: Initial project discussions
• December 2023: Solution confirmation
• January 2024: Order confirmation and start of equipment production
• May 2024: Equipment shipment
• July 2024: Equipment arrival
• August 2024: On-site installation
• September 2024: Commissioning completed and production officially started

Sabtech engineers completed the installation and commissioning at the client’s factory. Training covered equipment operation, routine maintenance, basic troubleshooting, production process coordination, safety precautions, and formulation adjustment, helping the client’s team adapt to the production requirements of the continuous foaming line.

Production Results

The continuous foaming line officially entered production in September 2024, achieving an actual output of approximately 500 cubic meters per day and exceeding the client’s expectations.

Based on its performance after start-up, the line has maintained stable control of key parameters, including raw material ratios, temperature, and finished foam density, during extended continuous operation. This has improved production stability and efficiency.

The estimated investment payback period for the project is approximately three years.

Ongoing Repeat Orders After Start-Up

After the project entered operation, the client continued to purchase the following products from Sabtech:

• Additional mass flow meters
• Manual foam transfer trolleys and battery-powered automatic foam transfer trolleys
• Repeated purchases of foaming raw materials and mattress materials
  

These subsequent purchases further strengthened the client’s production setup and continued to support the material requirements of its foam and mattress production.

Reference Value for Similar Projects

This project is particularly relevant to foam and mattress manufacturers that:

• Currently use batch foam machines and plan to upgrade to continuous foaming
• Face density fluctuations, inconsistent foam structure, insufficient capacity, or low automation
• Lack experience in operating a continuous foaming line
• Have stable market demand and need to expand production capacity while improving cost control
• Require coordinated support covering equipment, raw materials, mattress materials, installation, training, and ongoing production

The core of this project was the transition from the client’s existing batch foaming system to continuous production. In addition to replacing the equipment, the client also needed to adapt its operating methods, formulation adjustment, and production management to the requirements of continuous production.

For manufacturers planning a similar upgrade, the equipment solution should be evaluated based on production requirements, product types, operator capabilities, raw material supply, technical training, and ongoing production support.