In September 2021, we received an inquiry from Mr. Abdullah in Saudi Arabia regarding a continuous foaming machine. The client was planning to establish a PU foam factory to produce products for the local and Yemeni markets. He had some basic knowledge about machine usage and selection.



The client had no prior experience in foam production before, so he was particularly concerned about after-sales support and technical assistance.



We began by analyzing the client's target market (specific industry) and understanding the local product requirements (such as foam density, hardness, etc.) to confirm the client's production needs.



Through video conferences, we guided the client through our PU foam production process, providing the client with a concrete understanding of foam production and highlighting the convenience and efficiency advantages of our machines compared to those of other manufacturers.



Drawing upon our more than 20 years of experience in foam foaming, we shared insights with the client about using the machine and common challenges in the foam foaming process, addressing any technical concerns the client may have had.



We also provided the client with factory layout plans to expedite the setup of the entire foam production line while maximizing production efficiency.

Due to the client's high level of trust in our professional service, he ultimately chose us as his supplier for foam machinery and later made repeat purchases for a rebonded foam production line and foam cutting machines.

Polyurethane material is a block polymer containing carbamate characteristic groups produced by the reaction of polyisocyanate and hydrogen donor. Because of the various appearance forms of the generated products, its application has entered various fields of the world economy. The following is an overview of the horizontal continuous production line for polyurethane flexible block foam.

1. Hennecke flat top method

The continuous production line equipment for large-scale flexible polyurethane foam blocks was designed and put into production by Hennecke Company in Germany in 1952, which is the basis for continuous production of polyurethane foam blocks. Many companies have successively designed and manufactured continuous production lines for various forms of block bubbles, but only the basic principles designed by Hennecke have been used to this day. The production equipment is shown in Picture 1.



Pic 1 Schematic diagram of Hennecke polyurethane soft foam flat top continuous foaming production line

The polyurethane flexible foam continuous production line produced by Hennecke consists of several main parts: raw material supply section, mixing and pouring section, foaming and curing section, cutting section, post-curing section, and post-processing of the product. This production line has high production efficiency and requires a large supply of raw materials. Therefore, in addition to equipping tanks for polyols and isocyanates, separate systems for raw material storage, process parameters, condition control, and preparation are necessary to ensure a continuous supply of prepared raw materials to the production line during continuous operation (Picture 2).





Pic 2: Metering supply systems and mixing head input systems for 22 components

Temperature has a significant impact on the foaming reaction, and strict control of raw material temperature is necessary during foaming. Typically, the temperature is controlled within the range of 18 to 25°C, with a temperature fluctuation range of around 1°C. High-precision metering pumps are used for the metering and delivery of raw material components, with a general viscosity range of less than 2000 mPas. For high viscosity components such as colorants and flame retardants, gear pumps can be used. To prevent leakage of isocyanate components, the use of magnetic couplings is recommended. For convenience of operation and improved metering accuracy, some additives are now combined to reduce the number of metering pumps. However, it's important to note that certain additives, such as organic tin catalysts, are sensitive to other components and prone to degradation.

The mixing device used in this production line typically employs a low-pressure mixing head, with the agitator driven by a variable-speed motor at a rotational speed of 3000 to 6000 r/min. In modern continuous block foam production enterprises, high-pressure metering, mixing, and foaming equipment have also been adopted, allowing for adjustments in the mixing head's stirring form, flow rate, and nozzle size to enhance product quality. An air input device can also be configured at the mixing head to create gas nuclei and generate a fine and dense cell structure.

Well-mixed material is continuously discharged from the mixing head under certain pressure. To prevent material splashing and the entrapment of a large amount of air causing large voids within the foam body, various measures are taken during the foaming process. Apart from reducing the distance between the mixing head and the bottom plate and minimizing impact force, special designed baffles, horn-shaped or duckbill-shaped deflection tubes, and metal meshes are installed in the front part of the mixing head's outlet to reduce the impact energy of the material.

Meanwhile, the distance from the material outlet pipe to the bottom plate needs to be decreased to around 10 mm. To ensure the uniformly distributed material on the bottom plate, cross beams are set up on the production line. The mixing head can be adjusted to move left and right in coordination with the bottom plate conveyor belt's movement speed. Alternatively, the material can be divided into multiple conduits to enter distribution slots arranged laterally in the direction of the bottom plate's movement, ensuring the material is evenly distributed on the conveyor belt, as shown in Picture 3.



Pic 3 In order to prevent the spit out material from splashing, the mixing head is equipped with some deflectors

The material ejected from the mixing head exhibits good flowability before the emulsification time. As the reaction progresses, the mixed material gradually initiates and expands. At the front end of the conveyor belt in the ejection section, the conveyor belt should be inclined at an angle of 3° to 9° and equipped with hydraulic or manual adjustment devices. This allows for appropriate adjustments of the incline angle according to process requirements, ensuring the material flows and initiates uniformly in one direction. If the incline angle is too small or the conveyor belt's movement speed is too slow, the foam thickness increases, and initiating the foam becomes difficult. If the incline angle is too large, the ejected material will flow too quickly, reaching the lower part of the foam layer that has already started to rise, causing cracks in the foam body.

Typically, for high-flow-rate units, the conveyor belt's movement speed is controlled at 3 to 10 m/min, while for medium-sized units, it's controlled at 1.5 to 3 m/min. During operation, it's crucial to carefully adjust process parameters such as the ejection rate, conveyor belt angle, and movement speed to maintain a suitable distance of 300 to 600 mm between the ejected distribution line and the milky line formed during foam initiation.

The mixed material ejected from the mixing head is directly distributed onto the pre-laid liner paper on the conveyor belt. In the foaming section, a conveying and recovery device is assembled, including conveyor belts, a drying tunnel, side guards, and foam liners. In the past, a three-liner system was commonly used, with liner paper on the left and right sides moving synchronously with the foam body along the exhaust duct, while the bottom liner paper moved forward in sync with the conveyor belt. In the past, the upper part of the foam body was not restricted, resulting in a wasteful arched shape. Subsequently, the Hennecke-Planidiock method (see Picture 4) and the Hennecke flat-top foaming method (see Picture 8-5) were invented. The improved Hennecke flat-top method is now widely used.



Pic 4 Hennecke-Planidiock method





Pic 5 Schematic diagram of Hennecke flat-top foaming process

Both of the aforementioned production methods are equipped with mechanical balance pressure plates on the upper part of the rising foam body to reduce the volume of arched waste generated at the top of the foam body. Currently, the equipment for Hennecke's flat-top foaming often employs four liner papers synchronized to move in the upward, downward, leftward, and rightward directions along with the conveyor belt.

The lining materials for the foam body include specialized liner paper and plastic film. The base material of the liner paper is strong and durable kraft paper, treated with release agents such as polydimethylsiloxane or paraffin, or coated with non-adhesive chemicals like polyethylene. In recent years, some production facilities have begun using cost-effective plastic films like polyethylene, but it's important to ensure that the film does not crease during operation. Regardless of the lining material, it must remain flat and free of folds during operation.

In the foaming section's drying tunnel, the foam body expands and foams on the liner paper of the conveyor belt. Depending on the specific production formulation, the heat generated by the material's reaction or external heat sources are utilized to expedite the foam body's reaction, curing, and solidification, achieving the desired strength and performance for the subsequent process. The drying tunnel is equipped with multiple exhaust devices to remove various harmful gases produced by the foam body. After purification, these gases are released into the atmosphere.

The conveyor belt system for the foam body requires an extremely smooth surface and operates very steadily without any vibrations. The spacing between the side guards can be adjusted within a certain range as needed, allowing the production of rectangular foam bodies of different widths. The width can reach up to 2.2 meters, and the height of the produced foam bodies generally exceeds 1 meter.

After passing through the drying tunnel, although the foam body has not yet reached its maximum performance, it has been shaped. To facilitate subsequent stages of work, an online assembly cutting machine is used to cut the foam body into desired lengths. Following this, post-curing is performed to ensure complete reaction before further processing.

2. Maxfoam down-moving foaming method

The Maxfoam method, also known as the downward foaming method, was invented by Norwegian scientist Leader Berg in 1959. It employs a distinctive approach, where the foam foaming bottom plate moves downward. The fundamental principle involves raising the front end of a movable bottom plate to a position approximately 70% of the anticipated final foam height. This allows the entire bottom plate to be inclined downward. As the poured material rises to around 30% of its foam height, the lower bottom plate moves downward at the foam's rate of expansion. This causes the remaining 70% of the foam's height to expand downward, resulting in a foam body with a rectangular cross-section. The principle and equipment can be seen in Picture 6. Leader Berg used this principle to design and develop the renowned Maxfoam downward foaming process, depicted in Picture 7.



Pic 6 Schematic diagram of the principle of bottom plate moving down method





Pic 7 Schematic diagram of Maxfoam down-moving foaming process

In the development of the Maxfoam production apparatus, Leader Berg initially placed a baffle at the discharge point of the mixed material. This gradually evolved into an elongated downward foaming trough, and the flat plate where the material flowed was transformed into a downward-inclined bottom plate. This alteration changed the foam body's upward expansion during initiation to a downward expansion, leading to the creation of the renowned Maxfoam foaming process. Leader Berg's company has been dedicated to the research, development, production, and sales of flexible polyurethane block foam production processes and equipment, becoming one of the most prominent companies in this field. The basic process flow can be seen in Picture 8.



Pic 8 Maxfoam equipment produced by Hennecke

(1)The cross-section of the produced foam body is in a regular rectangular shape, leading to a significant reduction in waste rate and a high yield of finished products. In traditional processes, waste from edge and corner cuts is approximately 15%. In the Draka edge sliding method, it's around 12%. However, the waste generated by the Maxfoam process is less than 8%. With further improvements, such as using rotating forks, traction, and flattening devices covered with polyethylene film to fully envelop the foam body (see Picture 9), and utilizing the heat generated by the reactants to heat the bottom plate to make the lower skin of the foam thinner, waste can be lowered to 1% to 2%.



Pic 9 Laying polyethylene thin turning fork (a) device (b) and flattening device (c)

(2) The equipment is well-designed, precisely manufactured, accurately controlled, with a long lifespan, low production costs, and typically requires only 3 to 4 personnel for operation, with low maintenance costs.

(3) The unique foaming process ensures that the produced foam body has a uniform and consistent density, fine cell structure, and excellent quality.

(4) A typical control panel or an enhanced computer system monitors the entire production process with precision.

(5) The range of applicable raw materials is extensive, including both polyether and polyester types. Various types of foam bodies can be produced, including standard flexible foam as well as high-resilience foam, flame-retardant foam, filled foam, viscoelastic foam, and foam produced using carbon dioxide foaming.

In 1960, Leader Berg established his own company, Laader Berg AS, dedicated to the research and production of continuous polyurethane foam production equipment. The key components of the basic MaxformTM foaming machine are the Multi Trough (Picture 10) and the drop plate. As shown in the equipment schematic in Picture 11, the mixed materials are conveyed through multiple pipes to the bottom entry of the multi-trough. The material begins to react in the multi-trough and flows onto the bottom liner paper sliding on the inclined drop plate just before the emulsification of the mixed liquid. The foam from the multi-trough evenly overflows and spreads between the two side walls of the drop plate. The overflow volume of the multi-trough can be adjusted based on the foaming formula and production volume, and its outlet height is set at 70% of the final foam height.

Simultaneously, the angle, quantity, length, and width of the inclined drop plate can be adjusted according to the formula and production volume, ensuring that the foam body completes its full expansion process when it reaches the horizontal conveyor belt. During the downward flow of the foam body in the foaming channel of the drop plate, the friction between the foam body and the side walls is eliminated by downward gravity, resulting in a more uniform and smooth foam structure on both sides of the foam body. The foam body discharges the waste gases produced during production in the foaming channel, completes the maturation of the foam body, and can then proceed to the cutting process.



Pic 10 Multiple slots for Maxfoam foam machine multi trough



Pic 11 Basic MaxfoamTM Schematic

Our company also produces this kind of production line on the basis of this foaming method. The introduction reference is as follows (see Picture 12)

Technical parameters of SAB-CF02 automatic horizontal continuous foaming production line produced by Sabtech Technology

1. Main machine specification: total length 42m × width 6m × 4m

2. Foam sponge width: 915mm ~ 2350mm

3. Foaming height: below 1300mm

4. Foaming speed: 1500rpm ~ 7000rpm

5. Maximum output: 350kg / min

6. Spraying mode: The way of trough device, with inverter controlling

7. Foam box specification: L21m * W4.5m * H3m

8. Oven inner conveyer line (standard): L27m * W2.6m * H0.8m

9. Oven side links(standard) L21m * H1.3m

10. Drop frame: 7 sections of electric adjustment height / 0.2KW deceleration motor chain is used to drive rack adjustment between each section of plate

11. Side paper lifting device: front and rear electric movement, lift lever height electric adjustment, left and right-side independent control.

12. Side film collect and release system: the side film and lifting film releasing device is equipped with motor drive, the side film adopts magnetic powder clutch device to automatically reel in.

13. Bottom paper storage system.

14. Exhaust fan: 3kw * 2 sets (excluding exhaust pipe).

15. Constant temperature system: 20HP air-cooled cold and hot thermostat. Proportional valve is installed at the front inlet of tank coil, and raw material temperature is controlled and set.

16. Powersupply:3phrase 380V 50HZ



Figure 12 Sabtech Technology Limited horizontal continuous foaming unit3

3. Vertical Foam Method

In 1971, the UK-based company Hyman Development Corporation developed a unique vertical foam process technology and equipment. The apparatus mainly consists of a material storage tank system, metering conveying system, mixing injection system, barrel-shaped foaming device, heating and foam lifting device, as well as a cutting mechanism (see Picture 13).



Pic 13 Schematic diagram of vertical foaming equipment

The material storage tank system consists of five main components: raw material tanks (equipped with temperature control and stirring devices) for PPG, with TDI as the primary raw material, mixed with water, oil, amine catalyst, additives, MC foaming agent, and organic tin catalyst. Their metering and conveying systems generally use gear pumps driven by stepless speed-regulated motors, and flow meters can also be added to enhance metering accuracy. Low-pressure, agitating-type mixing heads are typically chosen. Once the materials are mixed, they are injected through pipelines from the bottom into the conical foam bucket. The foam bucket is pre-fitted with continuous sheets of polyethylene film. As the mixed materials react and foam, they initially move horizontally, filling the conical cross-section and gradually rising as the cross-section expands, eventually filling the polyethylene film-lined bucket and moving upward into the heating section. An electric heating system surrounds the heating section to expedite the foam maturation process.

The foam's ascent is facilitated by vertical conveyors equipped with fine needles (10-15mm in length). Multiple such conveyors are arranged around the entire foam body, with their fine needles embedded in the foam of a certain strength. As the conveyor belt rotates, the foam is gradually lifted. The upper part of the equipment is equipped with a cutting machine and a linked clutch mechanism that activates the cutting machine when the foam body reaches the designated height. The cut foam pieces are transported along an inclined slide to the post-maturation chamber.

This process can produce foam bodies with either square or circular cross-sections, simply by changing the shape of the foam bucket. During continuous production, the foam's color can be changed online, with a transition zone of only 150mm. This not only facilitates easy color changes but also maintains a high yield of finished foam products. The density and hardness performance on the foam's cross-section are consistent, and the foam's skin thickness at the edges is thin, resulting in low waste rates. Importantly, vertical foaming equipment occupies a smaller footprint, only a quarter of that of traditional horizontal foaming equipment, making it suitable for small and medium-sized enterprises. The products are not only suitable for general soft foam products but also the sliced circular foam bodies are particularly suitable for use as clothing lining materials.

The vertical foaming process imposes stricter requirements on aspects such as raw materials, formulations, and production process adjustment and control, compared to the production process of horizontal block foams. Precise control of various process parameters such as raw material temperature, formulation ratios, foam discharge rate, air injection rate, mixing speed, maturation section temperature, and traction speed is necessary to produce high-quality foam. In actual production, the following issues are prone to occur and must be addressed:

1.High Foam Closed Cell Rate or Shrinkage:

This can result from excessive use of organic tin catalyst, leading to rapid gelation during foaming and excessive growth of pore wall strength. Additionally, an excess of foam stabilizer can hinder the formation of open-cell foam structure due to its excessive stability.

2.Foam Body Cracking:

Foam body cracking is often due to errors in formulation or metering. Insufficient amounts of organic tin catalyst and foam stabilizer can lead to decreased reactivity. Mechanical factors, such as the presence of impurities, oil contamination within the foam body, and fluctuations in traction speed, can also contribute to extensive foam body cracking.

3. Large Bubble Cavities in Foam Body:

When large bubble cavities appear in the foam body, it is important to thoroughly inspect the following aspects: When there is a regular distribution of air bubbles, check whether there are any air leakage issues in the mixing chamber, feed pipes, and other equipment. If there are a few conical large bubbles present, it could be due to excessively high raw material temperature, causing the foaming agent to vaporize more easily. When the foam body exhibits irregularly distributed large air bubbles, the main cause could be excessive mixing speed resulting in a higher amount of entrapped air. Typically, with a well-sealed mixing head, the mixing speed should be controlled within the range of 2500 to 3000 rpm. If large perforations or interconnected bubbles appear in the foam sheet without a clear network structure, it might be due to excessive air input into the mixing head.

4.The Foam Body Sliding Downward：

This issue should be considered from several aspects, including formulation errors, excessive foaming time, insufficient foaming, excessively low maturation temperature, and improper coordination of the traction conveyor. It is a problem that can easily occur in the initial stages of equipm



Pic 14 Schematic diagram of the production process of the polyurethane flexible foam pressure-swing foaming continuous production line device

(1) Open the middle chamber door 3a and close the exit chamber door 3b. Activate the pressure control system 4a4b to bring the pressure in the entire channel to the set pressure value. The typical pressure range is 50 to 150 kPa (0.5 to 1.5 atm).

(2) Start the foaming machine, and the mixed material enters the overflow trough in the enclosed channel and flows to the drop plate for foaming under the set pressure environment.

(3) After the foam body is preliminarily cured and shaped to a certain length, the cutting machine operates to cut it.

(4) The cut foam body enters the post-area of the channel. Close the middle chamber door, adjust the pressure in the rear area to be equal to the ambient pressure, open the exit chamber door, and transport the foam body to the curing area to complete the curing. At the same time, the exit chamber door should be closed immediately, and the pressure regulation device should be activated immediately to equalize its pressure with the pressure in the entire channel. Then, open the middle chamber door to accommodate the next cut foam body.

This production line is monitored by highly automated computers, with segment control of the channel, cycle switching, and pressure adjustment system. Depending on the sealed channel, whether it's a vacuum or pressure vessel, it can produce foam bodies with rectangular or circular cross-sections. Based on this continuous production line, intermittent production lines with box-type variable pressure foaming have also been developed. Although the production efficiency is high, the control system is complex, and the equipment is bulky, with sealed channel lengths often exceeding hundreds of meters, resulting in significant investment.

The above provides an introduction to the horizontal continuous production line for flexible polyurethane foam blocks. Hope it can help you how to choose polyurethane flexible foam continuous production line. Welcome to leave a comment and discuss with me more about polyurethane foam.

1. Core Scorching (Center temperature exceeding material's oxidation temperature)

A. Poor quality polyether polyols: excessive moisture, high peroxide content, high boiling point impurities, elevated metal ion concentration, improper use of antioxidants.

B. Formulation issues: high TDI index in low-density formulas, improper ratio of water to physical blowing agents, insufficient physical blowing agent, excessive water.

C. Climate impact: high summer temperatures, slow heat dissipation, high material temperatures, high humidity leading to center temperature surpassing oxidation temperature.

D. Improper storage: Increased TDI index leading to accumulation of heat during post-curing, resulting in elevated internal temperature and core scorching.



2. Large Compression Deformation



A. Polyether Polyol: Functionality less than 2.5, propylene oxide ratio greater than 8%, high proportion of low molecular weight components, unsaturation greater than 0.05 mol/kg.

B. Process Conditions: The reaction center temperature is too low or too high, poor post-curing, incomplete reaction, or partial scorching.

C. Process Formula: TDI index too low (controlled within 105-108), excess silicone oil stannous octoate and silicone oil, low foam air content, high closed-cell content.



3. Soft Foam (Decreased hardness at same density)

A. Polyether polyols: low functionality, low hydroxyl value, high molecular weight.

B. Process formulation: insufficient T9 octoate, slow gelation reaction, lower water content with the same amount of tin catalyst, higher amount of physical blowing agents, high dosage of highly active silicone oil, low TDI index.



4. Large Cell Size

A. Poor mixing: uneven mixing, short cream time; increase mixing head speed, reduce mixing head pressure, increase gas injection.

B. Process formulation: silicone oil below lower limit, insufficient or poor quality octoate tin, slow gelation speed.



5. Density Higher than Set Value

A. Polyether polyols: low activity, high molecular weight.

B. Process formulation: silicone oil below lower limit, low TDI index, low foam index.

C. Climate conditions: low temperature, high pressure. A 30% increase in atmospheric pressure increases density by 10-15%.



6. Collapsed Cells and Hollows (Gas evolution rate greater than gelation rate)

A. Polyether polyols: excessive acid value (affects reaction rate), high impurities, low activity, high molecular weight.

B. Process formulation: excess amine, low tin catalyst (rapid foaming and slow gelation), low TDI index, insufficient or ineffective silicone oil.

C. Low-pressure foaming machine: reduce gas injection and mixing head speed.



7. High Closed-Cell Ratio

A. Polyether polyols: high epoxy ethane ratio, high activity, often occurs when switching to polyether polyols with different activity levels.

B. Process formulation: excessive octoate tin, high isocyanate activity, high crosslinking degree, high crosslinking speed, excessive amine and physical blowing agents leading to low foam pressure, high foam elasticity resulting in poor cell opening, excessively high TDI index leading to high closed-cell ratio.



8. Shrinkage (Gelation rate greater than foaming rate)

A. High closed-cell ratio, shrinkage during cooling.

B. Process conditions: low air and material temperature.

C. Process formulation: excessive silicone oil, less amine, more tin, low TDI index.

D. Low-pressure foaming machine: increase mixing head speed, increase gas injection.



9. Cracking

A. "八" shaped cracks indicate excess amine, single line cracks indicate excess water.

B. Mid and bottom cracks: Excessive amine, fast foaming rate (excessive physical blowing agent, poor silicone oil and catalyst quality).

C. Top cracks: Unbalanced gas-evolution gelation rate (low temperature, low material temperature, insufficient catalyst, less amine, poor silicone oil quality).

D. Internal cracks: Low air temperature, high center temperature, low TDI index, excessive tin, high early foaming strength, highly active silicone oil in small quantities.

E. Side middle cracks: Increase tin dosage.

F. Cracking throughout the process may be due to discrepancies in dropping plate and foaming reaction, or premature foaming, or incorrect plates. Apart from formulation, it also relates to the smoothness of the base paper; if the base paper is wrinkled, it can divide the liquid into several parts, causing cracks.



10. Blurred Cell Structure

A. Excessive stirring speed.

B. High air injection volume.

C. Inaccurate metering pump flow.

D. Clogged material pipelines and filters.



11. Bottom Edge Cracks (Excessive amine, fast foaming rate)

Surface large pores: excessive physical blowing agent, poor silicone oil and catalyst quality.



12. Poor Low-Temperature Performance

Poor inherent quality of polyether polyols: low hydroxyl value, low functionality, high unsaturation, low TDI index with the same tin usage.



13. Poor Ventilation

A. Climate conditions: low temperature.

B. Raw materials: high polyether polyol content, highly active silicone oil.

C. Process formulation: excess tin, or low tin and amine content with the same tin usage, high TDI index.

14. Poor Rebound

A. Raw materials: high activity polyether polyols, low molecular weight, highly active silicone oil.

B. Process formulation: high silicone oil content, excessive tin, high water content with the same tin usage, high TDI index, large amount of white oil and powder.



15. Poor Tensile Strength

A. Raw materials: excessive low molecular weight polyether polyols, low functionality hydroxyl value.

B. Process formulation: insufficient tin, poor gelation reaction, high TDI index with the same tin usage, low water content, low crosslinking.



16. Smoke during Foaming

Excessive amine release a large amount of heat during water and TDI reaction, causing evaporation of low-boiling substances and smoke. If not core scorching, smoke mostly consists of TDI, low-boiling substances, and monomer cycloalkanes in polyether polyols.



17. Foam with White Streaks

Fast foaming and gelation reaction but slow transfer in continuous foaming, resulting in a dense layer due to localized compression, causing white streaks. Increase transfer speed or lower material temperature, reduce catalyst usage.



18. Brittle Foam

Excessive water in the formulation leads to excess biuret formation, which does not dissolve in silicone oil. Poor use of tin catalyst, insufficient cross-linking reaction, high content of low molecular weight polyether polyols, high reaction temperature causing ether bond breakage and decreased foam strength.



19. Foam Density Lower than Set Value

Foam index is too high due to inaccurate measurement, high temperature, low pressure.



20. Foaming with Skin, Edge Skin, and Bottom Air

Excessive tin, insufficient amine, slow foaming rate, fast gelation rate, low temperature during continuous foaming.



21. Elongation Rate Too High

A. Raw materials: high activity polyether polyols, low functionality.

B. Process formulation: low TDI index, insufficient cross-linking, high tin.



22. Uncontrolled Foam (Small bubbles rapidly moving beneath surface)

A. Low-pressure foaming machine: increase mixing head speed, decrease gas injection.

B. High-pressure foaming machine: increase mixing head pressure.



23.Milky Moving Lines

A. Increase conveyor speed

B. Adjust cushion plate inclination.

C. Reduce amine catalyst usage



24.Inserted Material Backflow

A. Increase conveyor speed.

B. Adjust cushion plate inclination.

C. Increase amine catalyst usage.



25.Moon Pits

A. Low-pressure foaming machine: reduce mixing head speed and gas injection.

B. High-pressure foaming machine: increase mixing head pressure.

C. Silicone oil quality issue.

D. Increase amine amount while reducing tin amount to ensure adequate cell opening.



26.Slow Curing,Sticky Surface

Polymer strength increases too slowly, resulting in soft, sticky foam that is difficult to cut.

Foam blocks appear unstable when exiting channels.

Increase catalyst usage, check polyol, water, and TDl measurement accuracy.

Polyurethane soft foam plastic is one of the important products in the polyurethane industry. Its production necessarily involves the use of organic amine catalysts, especially organic tertiary amine catalysts. This is because organic tertiary amine catalysts play a significant role in the main reactions of polyurethane foam formation: the reactions of carbon dioxide and molecular polymerization, promoting rapid expansion of reaction mixtures, increased viscosity, and sharp increase in polymer molecular weight. These conditions are essential for the formation of foam bodies, ensuring that soft foam plastics have advantages such as low density, high strength-to-weight ratio, high resilience, and comfort for sitting and lying. There are many types of organic amine catalysts that can be used for polyurethane soft foam plastics. Among them, the highly efficient catalysts recognized by various manufacturers are: triethylene diamine (TDEA) and bis(dimethylaminoethyl) ether (referred to as A1). These are also the most widely used organic amine catalysts in the world today, with the highest consumption among various catalysts.



Due to the molecular structural differences between TDEA and A1 catalysts, there are significant differences in their catalytic performance, particularly in their reactions to carbon dioxide gas and molecular polymerization. If the user does not pay attention to these differences in production, not only will they fail to produce qualified foam products, but it will also be difficult for foam bodies to form. Therefore, understanding and mastering the performance differences between these two catalysts in polyurethane foam production is of great significance. TDEA exists in a solid state under normal conditions, making its application less convenient. In actual production, low molecular weight alcohol compounds are commonly used as solvents, formulated into 33% solutions for ease of use, commonly referred to as A33. On the other hand, A1 is a low-viscosity liquid that can be directly applied. Below is a comparison of the catalytic performance differences between A1 and A33 in the production of polyurethane soft foam plastics.



A33 has a 60% catalytic function for the reaction with carbon dioxide gas and a 40% catalytic function for molecular polymerization. It has a low effective utilization rate of carbon dioxide gas, resulting in lower foaming height and higher foam density. Since most of the catalytic function is used for molecular polymerization reactions, it is easy to produce closed-cell foam bodies, which are stiff with low rebound, and the adjustable range of tin catalysts becomes narrower. To achieve the same catalytic function, the amount used is 33% more than A1. Both the bottom skin and outer skin of the foam body are thicker. Increasing the amount can increase the reaction speed, but the amount of tin catalyst must be reduced accordingly, otherwise closed-cell foam bodies will be produced.



A1 has an 80% catalytic function for the reaction with carbon dioxide gas and a 20% catalytic function for molecular polymerization. It has a high effective utilization rate of carbon dioxide gas, resulting in higher foaming height and lower foam density. Since most of the catalytic function is used for gas generation reactions, it is easy to produce open-cell foam bodies, which are soft with high rebound, and the adjustable range of tin catalysts becomes wider. To achieve the same catalytic function, the amount used is less than A33. Both the bottom skin and outer skin of the foam body are thinner. Increasing the amount can increase the reaction speed, but the amount of tin catalyst must be increased accordingly, otherwise over-foaming and cracking may occur.



In terms of overall performance between TDEA and A1, A1 has a higher comprehensive catalytic performance than triethylene diamine. Its actual application effects are also better, although not as convenient as triethylene diamine in terms of transportation and storage. Currently, the vast majority of mechanical continuous foam production facilities almost exclusively use A1, while all box-type foam production facilities use TDEA. However, this is not absolute. With a clear understanding of the differences between the two and appropriate formulation adjustments, they can be interchangeable and both can produce excellent foam products.