End-to-end solutions from raw materials to production equipments for PU foam and mattress-Sabtech
One-Stop Flexible PU Foam Production and Supporting Solution for Mattress Factories
Based on your daily foam demand, target products, foam specifications, existing equipment, and factory conditions, Sabtech configures foaming, cutting, scrap utilization, and supporting mattress production equipment while providing layout planning, installation, commissioning, operator training, and start-up support.
Are You Facing Any of These Challenges?
PU Foam Production Solutions
Daily foam demand is an important reference when selecting a foaming method. Order stability, target foam products, product changeover frequency, project budget, factory conditions, and future expansion plans must also be considered.
If low-density foam dominates the local market and demand is relatively stable, a continuous foaming line should be evaluated first. Continuous production generally offers better material utilization and cost control for low-density foam.
Flexible Batch Foaming Solution
1–3 Tonnes per Day | 40–120 m³ per Day
Recommended Foaming MethodUse a batch foaming process. The specific foaming equipment should be selected according to the project budget, automation requirements, target foam products, and on-site production conditions.
The core configuration consists of foaming equipment, a vertical foam cutting machine, and a horizontal foam cutting machine. A circular foam cutting machine, foam slitting machine, CNC contour cutting machine, foam profiling machine, and other equipment can be added according to the required foam specifications and mattress products.
Foam shredding and rebonded foam production equipment can be added according to the actual scrap volume, available external scrap sources, and intended products.
Approximately 150–500 m² of factory space and 10–20 metres of straight-line production space.
Suitable for mattress factories with a relatively limited project budget or factory space, those beginning in-house foam production, those with smaller or fluctuating order volumes, and those requiring frequent foam product changeovers.
Continuous High-Volume Foaming Solution
5–15+ Tonnes per Day | 200–600+ m³ per Day
Use a continuous foaming line supported by suitable foam curing, handling, and turnover conditions.
The core configuration consists of a continuous foaming line, a vertical foam cutting machine, and a horizontal foam cutting machine. A circular foam cutting machine is recommended. A track-type horizontal foam cutting machine, CNC contour cutting machine, foam profiling machine, and other equipment can be added according to product specifications and cutting requirements.
Foam shredding and rebonded foam production equipment can be added according to the actual scrap volume, available external scrap sources, and intended products.
Approximately 1,000–3,000+ m² of factory space and 50–100+ metres of straight-line production space.
Suitable for mattress factories with stable orders, sustained foam demand, adequate investment and factory conditions, and a focus on long-term production consistency, material utilization, and high-volume production efficiency.
How Should a Factory Choose When Daily Foam Demand Is 3–5 Tonnes?
The foaming method for this output range should not be determined by volume alone.
A batch foaming solution can still be considered if orders fluctuate, products change frequently, or the project has relatively limited budget and factory space.
A continuous foaming line should be evaluated first if orders and foam demand are stable, low-density foam represents a large proportion of production, or there is a clear future expansion plan.
Project Scope: From Foam Production to Mattress Manufacturing
Sabtech configures foam production, cutting, scrap utilization, and mattress-related equipment according to the project stage and production conditions while supporting process integration and production start-up.
Sabtech provides Batch Foam Machines and Continuous Foaming Lines. The component system and equipment configuration are determined according to the target foam products, output, density, color, formulation, and automation requirements.
Available processes include vertical cutting, horizontal cutting, circular cutting, track-type horizontal cutting, foam slitting, CNC contour cutting, and foam profiling. The specific equipment is selected according to foam block format, foam dimensions, and finished-product requirements.
Foam shredding, rebonded foam production, and related processing equipment can be configured according to scrap type, volume, and intended use, connecting scrap handling with subsequent product manufacturing.
Available equipment covers quilting, border fabric processing, spring unit production, tape edging, mattress assembly, compression, packaging, and related production processes. The specific configuration is determined based on the mattress structure, production process, target output, automation requirements, and existing equipment.
According to whether the project involves a new factory, expansion, production upgrade, or equipment replacement, Sabtech plans equipment positioning and production flow across raw material storage, foaming, curing, cutting, handling, turnover, and mattress production.
Available services include project planning, equipment configuration, raw material and formulation support, installation, commissioning, operator training, trial-production adjustment, troubleshooting, spare parts, and long-term technical support. The specific service arrangement depends on the equipment and project conditions.
Related Projects
The following projects represent four common requirements: new factory development, business expansion, production upgrading, and equipment replacement. The equipment combination for each project depends on the customer’s existing business, target products, production conditions, and investment stage.
Russia
Malaysia
Libya
Morocco
Russia | New Foam Factory in Production
Expanding from Furniture Hardware into Flexible PU Foam Production
The customer originally manufactured furniture hardware and had long served local furniture factories. The new project was developed to produce conventional furniture foam, mattress foam, and mattress-related products while establishing foaming, cutting, and compression roll-packing capabilities.
Although the customer had manufacturing experience, it lacked mature flexible PU foam production experience. The project therefore needed to address foaming equipment, downstream cutting, raw material preparation, process and formulation support, and production start-up.
The project configuration included a 14-component Continuous Foaming Line, a Circular Foam Cutting Machine, a CNC Foam Cutting Machine, and an Automatic Mattress Compression Roll-Packing Machine. Sabtech also supplied foam raw materials, PE film, and PE-coated kraft paper and sent engineers to Russia for installation, commissioning, and training.
The project entered production in late July 2026, establishing production capabilities for conventional flexible PU foam, foam cutting, and compression roll packing of mattress-related products.
Malaysia | Mattress Factory Expanding Its Foam Production Capabilities
Expanding from Mattress Manufacturing into Rebonded Foam and In-House Foaming.
The customer already operated a mattress factory and planned to add rebonded foam production before gradually establishing its own flexible PU foam production capacity.
The customer was initially unfamiliar with rebonded foam equipment, raw material preparation, and the production process. The first-stage solution also needed to account for factory space, investment budget, process integration, and future expansion.
Sabtech configured a Rebonded Foam Machine according to the target density, hardness, factory conditions, and project budget. Guidance was also provided on raw material preparation, production procedures, and equipment operation. After installation, Sabtech engineers delivered targeted training to the customer’s production team.
Trial production was completed successfully, producing rebonded foam that met the project requirements. The customer later purchased a Semi-Automatic Batch Foam Machine and additional foam raw materials, further developing its in-house foaming capability.
Libya | Upgrading from Batch to Continuous Foaming
Improving Mattress Foam Output and Production Consistency
The customer produces mattress foam and mattresses. Its existing batch foaming equipment had a relatively low level of automation and was increasingly affected by density variation between batches, inconsistent foam structure, and insufficient capacity. The customer therefore decided to upgrade to continuous foaming.
The customer lacked experience in operating a continuous foaming line and was particularly concerned about equipment stability, process and formulation adjustment, technical support, and long-term operation after production start-up.
The initial configuration included a 16-component Continuous Foaming Line, a Vertical Foam Cutting Machine, mattress fabric and springs, as well as polyether polyol, polymer polyol, silicone surfactant, amine catalyst, and tin catalyst.
The 16-component system included nine components for base materials and additives, one black pigment tank, five additional color tanks, and one spare tank. This configuration was selected to meet daily output requirements, support production in different colors, and control costs through the use of powder fillers. The line was also equipped with a control system and foam height monitoring.
Sabtech engineers completed on-site installation and commissioning and provided training covering equipment operation, maintenance, troubleshooting, production procedures, safety, and formulation adjustment.
The 16-component system included nine components for base materials and additives, one black pigment tank, five additional color tanks, and one spare tank. This configuration was selected to meet daily output requirements, support production in different colors, and control costs through the use of powder fillers. The line was also equipped with a control system and foam height monitoring.
Sabtech engineers completed on-site installation and commissioning and provided training covering equipment operation, maintenance, troubleshooting, production procedures, safety, and formulation adjustment.
The production line officially entered operation in September 2024, with an actual output of approximately 500 m³ per day. After start-up, foam consistency improved significantly and raw material losses were reduced. The customer subsequently purchased a mass flow meter, a foam-pulling trolley, additional foam raw materials, and mattress materials.
Morocco | Replacing Aging Equipment and Expanding Foam Processing Capabilities
Updating Foam Shredding Equipment and Adding Contour Cutting Capability.
The customer is a mattress factory with 20 years of local operating experience. It produces flexible PU foam, mattresses, and rebonded foam, with most of its foam used in its own mattress production.
The existing Foam Shredder had become outdated, while the current cutting equipment could not process certain complex profiles. Local foam raw material supply and pricing were also unstable.
Sabtech supplied a new Foam Shredder for integration into the customer’s existing rebonded foam production process. A CNC Foam Cutting Machine was also configured to add contour cutting capabilities for flexible PU foam and rebonded foam.
The project additionally included amine catalyst, tin catalyst, silicone surfactant, and color pigments. Installation, commissioning, and training were completed remotely.
Both machines have entered production and have been integrated into the customer’s existing foam shredding, rebonded foam production, and contour cutting processes.
Why Choose Sabtech
First-Hand Production ExperienceLong-term experience in foam production, cutting and converting, scrap utilization, mattress manufacturing, and equipment operation provides a practical basis for project configuration and on-site problem assessment.
Coverage Across Multiple Production StagesEquipment and services cover raw materials, formulations, foaming, cutting, scrap recycling, mattress production, and packaging, reducing configuration and coordination problems between different supply stages.
Configuration Based on Project ConditionsEquipment combinations are determined according to target products, foam demand, factory conditions, operating experience, investment stage, and expansion plans rather than fixed packages.
Support for Start-Up and Long-Term Operation
Support covers installation, commissioning, operator training, trial-production adjustment, foam processes and formulation support, troubleshooting, spare parts, and ongoing technical service.
Planning for Future Expansion from the Initial StageThe initial configuration also considers future capacity growth, product changes, and equipment expansion, reducing the need for extensive later modifications and repeated investment.
1
When Should a Mattress Factory Consider Producing Foam In-House?
A mattress factory can evaluate in-house foam production when it has relatively stable foam demand or wants to reduce exposure to purchase-price and delivery risks, improve control over foam specifications and quality, develop customized mattress products, or sell foam to external customers.
The factory should also compare the total cost of long-term external purchasing with in-house production and assess whether sufficient capital, space, raw material supply, personnel, and production management capabilities are available.
The factory should also compare the total cost of long-term external purchasing with in-house production and assess whether sufficient capital, space, raw material supply, personnel, and production management capabilities are available.
2
What Is the Difference Between a Batch Foam Machine and a Continuous Foaming Line, and How Should a Factory Choose?
A Batch Foam Machine produces one foam block per batch. Its reference output is 1–3 tonnes per day, or approximately 40–120 m³, and it normally requires 3–6 operators. It requires less equipment investment and factory space and offers flexible product changeovers. However, production results depend more heavily on operator experience, while batch variation, trimming losses, and trial-foaming losses are generally more noticeable.
A Continuous Foaming Line has a reference output of 5–15+ tonnes per day, or approximately 200–600+ m³, and normally requires 5–10 operators. It requires greater investment and factory space but offers a higher level of automation and production standardization, with advantages in continuous production stability, material utilization, and low-density foam cost control.
When daily demand is 3–5 tonnes, the decision should consider order stability, product changeover frequency, the proportion of low-density foam, factory conditions, budget, and future expansion plans.
A Continuous Foaming Line has a reference output of 5–15+ tonnes per day, or approximately 200–600+ m³, and normally requires 5–10 operators. It requires greater investment and factory space but offers a higher level of automation and production standardization, with advantages in continuous production stability, material utilization, and low-density foam cost control.
When daily demand is 3–5 tonnes, the decision should consider order stability, product changeover frequency, the proportion of low-density foam, factory conditions, budget, and future expansion plans.
3
What Equipment and Raw Materials Are Normally Required for a Mattress Foam Production Project?
The core equipment includes foaming equipment, a Vertical Foam Cutting Machine, and a Horizontal Foam Cutting Machine. A Circular Foam Cutting Machine is generally recommended for continuous foaming projects. A Foam Slitting Machine, Track-Type Horizontal Foam Cutting Machine, CNC Contour Cutting Machine, Foam Profiling Machine, Foam Shredder, and rebonded foam equipment can be added according to the target products and scrap utilization plan.
The project also requires suitable conditions for raw material storage, foam curing, handling, and turnover.
Common raw materials include polyether polyol, polymer polyol, isocyanate, water, silicone surfactant, amine catalyst, tin catalyst, color pigments, auxiliary blowing agents, and other additives or fillers required by the formulation. The raw materials and equipment components must be matched to the target foam products.
The project also requires suitable conditions for raw material storage, foam curing, handling, and turnover.
Common raw materials include polyether polyol, polymer polyol, isocyanate, water, silicone surfactant, amine catalyst, tin catalyst, color pigments, auxiliary blowing agents, and other additives or fillers required by the formulation. The raw materials and equipment components must be matched to the target foam products.
4
How Much Investment Is Required for a Mattress Foam Production Project?
The main equipment investment for a batch foaming solution is approximately US$30,000–100,000, while the total project investment is approximately US$60,000–150,000.
The main equipment investment for a continuous foaming solution is approximately US$110,000–400,000+, while the total project investment is approximately US$250,000–900,000+.
These figures are intended for preliminary budgeting. Actual investment depends on production capacity, the number of components, automation level, cutting and scrap-processing equipment, transportation, installation, and initial raw material requirements.
The main equipment investment for a continuous foaming solution is approximately US$110,000–400,000+, while the total project investment is approximately US$250,000–900,000+.
These figures are intended for preliminary budgeting. Actual investment depends on production capacity, the number of components, automation level, cutting and scrap-processing equipment, transportation, installation, and initial raw material requirements.
5
What Foam Densities, Hardness Levels, and Colors Can Be Produced on the Same Foaming Equipment?
Within the component configuration and metering range of the equipment, the same foaming system can produce conventional mattress foam in different densities, hardness levels, and colors by adjusting raw materials, formulations, and process parameters.
For example, a nine-component continuous foaming configuration has a reference density range of 8–80 kg/m³ for conventional flexible PU foam. Special products such as high-resilience foam and memory foam require corresponding raw material components.
Density and hardness are different performance indicators, while the number of available colors depends on the color-component configuration.
For example, a nine-component continuous foaming configuration has a reference density range of 8–80 kg/m³ for conventional flexible PU foam. Special products such as high-resilience foam and memory foam require corresponding raw material components.
Density and hardness are different performance indicators, while the number of available colors depends on the color-component configuration.
6
How Much Factory Space Is Required for a New Foam Production Project?
A batch foaming project generally requires approximately 150–500 m² of factory space and 10–20 metres of straight-line production space.
A continuous foaming project generally requires approximately 1,000–3,000+ m² of factory space and 50–100+ metres of straight-line production space.
These figures are preliminary estimates for the overall project and already account for raw material storage, foaming, curing, cutting, handling, and turnover areas. The actual requirement must be calculated according to the equipment configuration, factory structure, and production arrangement.
A continuous foaming project generally requires approximately 1,000–3,000+ m² of factory space and 50–100+ metres of straight-line production space.
These figures are preliminary estimates for the overall project and already account for raw material storage, foaming, curing, cutting, handling, and turnover areas. The actual requirement must be calculated according to the equipment configuration, factory structure, and production arrangement.
7
How Can Foam Cutting Scrap Be Utilized, and When Is Rebonded Foam Production Suitable?
Relatively clean flexible PU foam scrap can be sorted and shredded for rebonded foam production or used as filling material, depending on the intended application.
Whether to add rebonded foam equipment should be determined according to the factory’s actual scrap volume, available external scrap sources, target products, factory conditions, and sales channels.
Whether to add rebonded foam equipment should be determined according to the factory’s actual scrap volume, available external scrap sources, target products, factory conditions, and sales channels.
Submit Requirements, Get Preliminary Configuration
If you are evaluating in-house foam production, expanding existing capacity, or upgrading related equipment for a mattress factory, please provide the following information:
• Whether the project involves a new factory, expansion, production upgrade, or equipment replacement;
• Daily foam demand;
• Target foam types, densities, hardness levels, and colors;
• Mattress types to be produced;
• Existing production equipment;
• Available factory area and straight-line space;
• Investment plan and future expansion direction.
Based on this information, Sabtech will evaluate a suitable foaming method, cutting equipment configuration, supporting mattress production equipment, and project implementation plan.
Over 20 years of first-hand production and usage experience, our technology development team aims to make every machine exhibit the characteristics of simplicity, labor efficiency, ease of operation, and minimal maintenance.
Contact Us
Contact Person: Cynthia Cheung
Contact Number: +86-15687268672
Email: sales@alforu.cn
WhatsApp: +86-15687268672
Company Address: Foshan City, Guangdong Province China
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