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Guide to Buy Mattress Compression Machine for Sale in ALFORU
Sabtech Technology Limited develops and produces mattress compression machine for sale for various application upon request. Its design starts with considering the needs of the user, but it is added with fashion, style, and personality thereafter, which makes the product aesthetic, fashionable, and practical. As product design, manufacturing processes, materials, and technology continue to improve, the product will be improved accordingly, showing a wider application in the future.
Our brand Sabtech touches customers and diverse buyers all over the world. It is a reflection of who we are and the value we can bring. At the heart, we aim to help our customers to be more competitive and attractive in a world with a growing demand for innovative and sustainable solutions. All product and service offerings are commended by our customers.
Our products like mattress compression machine for sale are well-recognized in the industry, so is our customer service. At Sabtech Technology Limited, customers can get a comprehensive and professional customization service. Customers are also welcomed to request samples from us.
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When using a batch foam machine for polyurethane soft foam foaming, have you encountered the following situations?
1.Uneven and numerous foam pores,
2. Rough foam texture.
3. Chaotic pore sizes across the entire foam surface, with slight signs of large pores.
Issues like these are quite common. The main reason for the first issue is that the distance between the mixing impeller of the foam machine and the bottom of the mixing barrel is too great; the second issue is that the mixing blades are too short and narrow: the third issue is that the angle of the mixing blades is too large.
Many manufacturers who design and produce foam machines only understand the principles during the design process, without understanding the significant relationship between a different design in foam production and product quality. A reasonable and perfect mechanical design can only be gradually improved in actual work, and only experienced foamers can achieve this.
Here are some experiences we have had with machine modifications and upgrades, hoping they will be helpful:
First, the installation position of the mixing wheel should be as low as possible, closer to the bottom of the mixing barrel is better. In general, the distance between the lowest point of the mixing blade and the bottom of the mixing barrel should be around two centimeters
Second, the shape of the mixing blade should be fan-shaped, with a moderately wide edge. The advantage of being wide is that it increases the contact area with the liquid material, providing sufficient power and also balances the liquid material.
Third, the length of the mixing blade should also be as long as possible, leaving about three to four centimeters from the baffle inside the mixing barrel.
Fourth, the two edges of the mixing blade should be sloped, with the angle of inclination based on the width of one end and two centimeters difference on both sides. After the mixing blade is modified, proper operation is also crucial, especially the mixing speed. Most batch foam machines nowadays are equipped with high-speed timing frequency conversion devices. However, in actual production, this device is often unnecessary. The operating speed mainly depends on the amount of material in the mixing barrel. If there is a lot of material, the speed should be appropriately faster, and if there is less material, then the speed should be lower.
1.Uneven and numerous foam pores,
2. Rough foam texture.
3. Chaotic pore sizes across the entire foam surface, with slight signs of large pores.
Issues like these are quite common. The main reason for the first issue is that the distance between the mixing impeller of the foam machine and the bottom of the mixing barrel is too great; the second issue is that the mixing blades are too short and narrow: the third issue is that the angle of the mixing blades is too large.
Many manufacturers who design and produce foam machines only understand the principles during the design process, without understanding the significant relationship between a different design in foam production and product quality. A reasonable and perfect mechanical design can only be gradually improved in actual work, and only experienced foamers can achieve this.
Here are some experiences we have had with machine modifications and upgrades, hoping they will be helpful:
First, the installation position of the mixing wheel should be as low as possible, closer to the bottom of the mixing barrel is better. In general, the distance between the lowest point of the mixing blade and the bottom of the mixing barrel should be around two centimeters
Second, the shape of the mixing blade should be fan-shaped, with a moderately wide edge. The advantage of being wide is that it increases the contact area with the liquid material, providing sufficient power and also balances the liquid material.
Third, the length of the mixing blade should also be as long as possible, leaving about three to four centimeters from the baffle inside the mixing barrel.
Fourth, the two edges of the mixing blade should be sloped, with the angle of inclination based on the width of one end and two centimeters difference on both sides. After the mixing blade is modified, proper operation is also crucial, especially the mixing speed. Most batch foam machines nowadays are equipped with high-speed timing frequency conversion devices. However, in actual production, this device is often unnecessary. The operating speed mainly depends on the amount of material in the mixing barrel. If there is a lot of material, the speed should be appropriately faster, and if there is less material, then the speed should be lower.
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.
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.
Flame-retardant PU flexible foam, also known as fireproof PU flexible foam, is generally a fireproof material synthesized by adding flame retardants to various polyurethane materials.
Function of flame retardants: They can absorb heat and decompose into non-combustible substances at or near the ignition temperature; they can react with the combustion products of the PU flexible foam to produce difficult-to-burn substances, thereby delaying combustion and allowing the ignition point to self-extinguish.
Common flame retardants: Bromine-based flame retardants, chlorine-based flame retardants, phosphorus-based flame retardants, and inorganic flame retardants.
Flame Retardant Grade and Testing for PU flexible foam
Flame retardant grade refers to the obvious property that a substance has or a material exhibits after treatment, which significantly delays the spread of flames.
Flame retardant testing:
HB: The lowest flame retardant grade in the UL94 standard. It requires that for samples 3 to 13 millimeters thick, the burning rate is less than 40 millimeters per minute; for samples less than 3 millimeters thick, the burning rate is less than 70 millimeters per minute; or extinguished before reaching the 100-millimeter mark.
V-2: After two 10-second combustion tests on the sample, the flame is extinguished within 60 seconds. Combustible material may drop.
V-1: After two 10-second combustion tests on the sample, the flame is extinguished within 60 seconds. There should be no combustible material dropping.
V-0: After two 10-second combustion tests on the sample, the flame is extinguished within 30 seconds. There should be no combustible material dropping.
Function of flame retardants: They can absorb heat and decompose into non-combustible substances at or near the ignition temperature; they can react with the combustion products of the PU flexible foam to produce difficult-to-burn substances, thereby delaying combustion and allowing the ignition point to self-extinguish.
Common flame retardants: Bromine-based flame retardants, chlorine-based flame retardants, phosphorus-based flame retardants, and inorganic flame retardants.
Flame Retardant Grade and Testing for PU flexible foam
Flame retardant grade refers to the obvious property that a substance has or a material exhibits after treatment, which significantly delays the spread of flames.
Flame retardant testing:
HB: The lowest flame retardant grade in the UL94 standard. It requires that for samples 3 to 13 millimeters thick, the burning rate is less than 40 millimeters per minute; for samples less than 3 millimeters thick, the burning rate is less than 70 millimeters per minute; or extinguished before reaching the 100-millimeter mark.
V-2: After two 10-second combustion tests on the sample, the flame is extinguished within 60 seconds. Combustible material may drop.
V-1: After two 10-second combustion tests on the sample, the flame is extinguished within 60 seconds. There should be no combustible material dropping.
V-0: After two 10-second combustion tests on the sample, the flame is extinguished within 30 seconds. There should be no combustible material dropping.
Beginners are concerned that if the settling plate is not adjusted properly, the liquid flowing out of the nozzle may cause front surging or back surging, affecting the foaming process. Within two minutes after starting the machine, the reaction speed gradually increases, sometimes requiring adjustments to the settling plate. Adjustments to the settling plate are more critical in low-density and high-moisture-content (MC) formulas.
TDI (Toluene Diisocyanate) flow rate can be calculated to correspond to the scale value, but it is recommended to actually measure the TDI flow rate during the first foaming. Flow rate is too important; if the flow rate is not accurate, everything else will be a mess. It's best to rely on the simplest and most intuitive method of measuring the flow rate.
When mixing powders, the mixed stone powder should be left overnight and production should start the next day. For ingredients containing melamine and stone powder, it is recommended to first mix melamine with polyether for a period of time before adding the stone powder.
Foam machine formulas with long mixing chamber in the machine head or more teeth on the stirring shaft usually have less amine and lower material temperature. Conversely, foam machine formulas with short mixing chamber in the machine head or fewer teeth on the stirring shaft usually have more amine and higher material temperature.
For the same formula, when switching between dual-spray swivel heads and single-spray swivel heads with similar nozzle cross-sectional areas, the requirements for mesh thickness and layers are similar.
For the calibration of minor material flow, one method is to measure the return flow of the minor material, and the other is to calibrate it by dividing the total amount used by the foaming time. When there is a significant difference between the two calibration methods, rely on the data from the second calibration method.
Formulas for high-quality soft foam are usually within an unstable range, such as a low TDI index, low water-to-MC ratio, low T-9 dosage, and low silicone oil dosage.
TDI (Toluene Diisocyanate) flow rate can be calculated to correspond to the scale value, but it is recommended to actually measure the TDI flow rate during the first foaming. Flow rate is too important; if the flow rate is not accurate, everything else will be a mess. It's best to rely on the simplest and most intuitive method of measuring the flow rate.
When mixing powders, the mixed stone powder should be left overnight and production should start the next day. For ingredients containing melamine and stone powder, it is recommended to first mix melamine with polyether for a period of time before adding the stone powder.
Foam machine formulas with long mixing chamber in the machine head or more teeth on the stirring shaft usually have less amine and lower material temperature. Conversely, foam machine formulas with short mixing chamber in the machine head or fewer teeth on the stirring shaft usually have more amine and higher material temperature.
For the same formula, when switching between dual-spray swivel heads and single-spray swivel heads with similar nozzle cross-sectional areas, the requirements for mesh thickness and layers are similar.
For the calibration of minor material flow, one method is to measure the return flow of the minor material, and the other is to calibrate it by dividing the total amount used by the foaming time. When there is a significant difference between the two calibration methods, rely on the data from the second calibration method.
Formulas for high-quality soft foam are usually within an unstable range, such as a low TDI index, low water-to-MC ratio, low T-9 dosage, and low silicone oil dosage.
Application of High Resilience Polyether Formulations:
For high resilience polyether, the most frequently used molecular weights are 5,000 and 6,000. The foam produced from high resilience polyether with a molecular weight of 5,000 does not have as good elasticity as that with a molecular weight of 6,000 and tends to be harder. On production lines with continuous foaming, the high resilience polyether with a molecular weight of 5,000 is more commonly used. Polyether polymers, like ordinary foams, are also white and viscous.
Let's look at the differences between ordinary foam formulations and high resilience formulations. Due to the high reactivity of high resilience polyether, it reacts strongly with TDI, suppressing the reaction between TDI and water. We will analyze each component based on the following formulations:
In the formulations, the PPG (polypropylene glycol) is the same. The TDI index is higher in high resilience polyether formulations, which results in the foam being less elastic and more difficult to open the cells. In contrast, the TDI index varies significantly in ordinary polyether foams.
Now, let's consider high resilience silicone oil. Given the high reactivity of high resilience polyether, the silicone oil used should not be highly reactive. In other words, using ordinary silicone oil for high resilience foam will result in severe closed cells; conversely, using high resilience silicone oil for ordinary foam will cause the foam to collapse because the low reactivity of this silicone oil cannot support the foam structure.
Next, let's look at amines. Both types of foam require amines, with variations in the amount used. Amines are quite reactive.
Now, let's consider tin. Since high resilience polyether is highly reactive, the amount of tin used will be relatively lower.
MC (methylene chloride) is also used in both formulations, but some formulations may omit it depending on the specific situation.
Another major difference is that high resilience polyether formulations use crosslinking agents, which is also due to the high reactivity of high resilience polyether. Can foam be produced without crosslinking agents? Yes, but the resulting foam will not have particularly good elasticity.
Some might ask if adding some high resilience polyether to ordinary foam can improve its elasticity due to its high molecular weight. This idea is feasible but needs to consider the following points:
If the ordinary foam formulation has very low density, do not add high resilience polyether because low-density formulations contain more TDI and water, leading to intense reactions. Adding high resilience polyether would make the reaction even more intense, counterproductive.
If the formulation contains a high amount of water, do not add high resilience polyether, as this could cause significant problems.
For high resilience polyether, the most frequently used molecular weights are 5,000 and 6,000. The foam produced from high resilience polyether with a molecular weight of 5,000 does not have as good elasticity as that with a molecular weight of 6,000 and tends to be harder. On production lines with continuous foaming, the high resilience polyether with a molecular weight of 5,000 is more commonly used. Polyether polymers, like ordinary foams, are also white and viscous.
Let's look at the differences between ordinary foam formulations and high resilience formulations. Due to the high reactivity of high resilience polyether, it reacts strongly with TDI, suppressing the reaction between TDI and water. We will analyze each component based on the following formulations:
In the formulations, the PPG (polypropylene glycol) is the same. The TDI index is higher in high resilience polyether formulations, which results in the foam being less elastic and more difficult to open the cells. In contrast, the TDI index varies significantly in ordinary polyether foams.
Now, let's consider high resilience silicone oil. Given the high reactivity of high resilience polyether, the silicone oil used should not be highly reactive. In other words, using ordinary silicone oil for high resilience foam will result in severe closed cells; conversely, using high resilience silicone oil for ordinary foam will cause the foam to collapse because the low reactivity of this silicone oil cannot support the foam structure.
Next, let's look at amines. Both types of foam require amines, with variations in the amount used. Amines are quite reactive.
Now, let's consider tin. Since high resilience polyether is highly reactive, the amount of tin used will be relatively lower.
MC (methylene chloride) is also used in both formulations, but some formulations may omit it depending on the specific situation.
Another major difference is that high resilience polyether formulations use crosslinking agents, which is also due to the high reactivity of high resilience polyether. Can foam be produced without crosslinking agents? Yes, but the resulting foam will not have particularly good elasticity.
Some might ask if adding some high resilience polyether to ordinary foam can improve its elasticity due to its high molecular weight. This idea is feasible but needs to consider the following points:
If the ordinary foam formulation has very low density, do not add high resilience polyether because low-density formulations contain more TDI and water, leading to intense reactions. Adding high resilience polyether would make the reaction even more intense, counterproductive.
If the formulation contains a high amount of water, do not add high resilience polyether, as this could cause significant problems.
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we welcome custom designs and ideas and is able to cater to the specific requirements. for more information, please visit the website or contact us directly with questions or inquiries.
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: Wenky Lau
Contact Number: +86-15687268672
Email: sales1@alforu.cn
WhatsApp: +86 15687268672
Company Address: NO. 18 South Industry Road, Dongguan City, Guangdong Province China
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