End-to-end solutions from raw materials to production equipments for PU foam and mattress-Sabtech

Guide to Shop Mattress Machinery for Sale in ALFORU

When manufacturing mattress machinery for sale, Sabtech Technology Limited puts emphasis on the quality control. We let our quality control inspectors protect the customers from defective products and the company from damage to our reputation due to inferior manufacturing processes. If the testing process reveals problems with the product, the inspectors will immediately solve them and make records, thus improve the efficiency of the product.

Many customers are satisfied with our products. Thanks to their high-cost performance and competitive price, the products have brought great benefits to customers. Since launched, they have received wide praises and attracted an increasing number of customers. Their sales are rapidly increasing and they have occupied a large market share. More and more clients from all over the world seek for cooperation with Sabtech for better development.

mattress machinery for sale is provided with a comprehensive and thoughtful service to traders around the world through the carefully designed Sabtech Technology Limited.

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Sabtech has enough technical support to keep improving our products.

Indonesian Foam Factory Equipment Upgrade Case

Project Background
In May 2022, we received an inquiry from a foam factory in Indonesia. The factory produced both rebonded foam and conventional PU foam for the local market.

This project focused on upgrading the conventional foam production section, where the customer was still using a fully manual batch foaming setup.

Why the Upgrade Was Needed
The original production setup had several clear limitations in daily operation:

Unstable process control
High material waste
Low production efficiency
Strong dependence on operator experience

For a factory already in regular production, these issues directly affected output consistency and material utilization. The customer therefore planned to replace its fully manual setup with a semi-automatic batch foam machine.

Production Issues That Also Needed Adjustment
During communication, the customer also raised two quality issues in conventional foam production:

Core scorching in low-density foam
Visible small holes in foam used for footwear

These issues affected product consistency and made daily production harder to control.

Technical Adjustment Before Final Equipment Matching

Before the final equipment configuration was confirmed, our foaming engineers provided remote technical guidance based on the customer's existing production conditions. The support covered formula and process adjustments, raw material selection, and equipment recommendations.

For core scorching in low-density foam, we adjusted the water content and other aspects of the formulation. For the visible small holes in foam used for footwear, keeping the raw materials at around 20°C helped reduce the occurrence of these defects in the customer's production.

Both issues had already improved through this technical support before the customer placed the equipment order.

Equipment Ordered

In July 2022, the customer placed an order for the following equipment:

Foam machines loading

On-Site Installation and Operator Training
Our team carried out installation at the customer's factory. During the on-site support, our foaming engineer trained the customer's team in:

Machine operation
Batch foam production
Process adjustment based on actual production conditions

This support helped the customer connect the new equipment with actual production more smoothly.

Foaming engineer on-site training

Semi-Automatic Batch Foam Machine Upgrade

The semi-automatic batch foam machine was the main equipment in this upgrade. Small additives still required manual weighing and addition, while the main operating steps were controlled through the PLC system.

Compared with the customer's original fully manual setup, this made daily operation easier to control and reduced dependence on individual operator experience.

Foam Top Flattening and Mold Size Adjustment

Top-Flattening Device

The device helped produce a flatter foam top, reducing crown trimming waste and improving material utilization.

Top-flat device

Adjustable Box Mold
The mold could be adjusted for different foam block dimensions, reducing the need for separate molds in multiple sizes.

Project Result

The technical adjustments resolved core scorching in the customer's low-density foam and reduced the occurrence of visible small holes in its footwear foam.

The equipment upgrade reduced material waste, improved production efficiency, and made operation more stable, with less dependence on individual operator experience.

Photo of a foaming engineer and customers

For foam factories still facing high material waste, unstable operation, or strong dependence on manual experience, Sabtech can help review the current production setup and match a more suitable upgrade solution.

Saudi Arabia PU Foam Factory Project Case

From a Continuous Foaming Line Inquiry to an Integrated Foam Production Setup

Project Background

In September 2021, we received an inquiry from Mr Abdullah, a client from Saudi Arabia. He planned to build a new PU foam factory serving the Saudi local market and the Yemeni market, mainly for furniture and mattress flexible PU foam products. He also planned to include downstream processing.

The client had local foaming workers and some basic production conditions in place. As the project moved forward, it required coordinated planning of target products, equipment configuration, factory layout, and the connection between foaming and downstream processing.

How the Project Scope Expanded

The client’s initial inquiry focused on a continuous foaming line. As the discussions progressed, the project scope expanded to include rebonded foam production and the cutting equipment required for downstream processing.

One important consideration was how the factory would handle foam offcuts after production increased. The local market for rebonded foam was relatively strong, while the local selling price for baled foam offcuts was low. As the planned production scale increased, the factory was expected to generate foam offcuts regularly. Processing this material into rebonded foam would provide greater long-term value than selling it directly as low-value scrap.

The client therefore decided to add a complete rebonded foam production line. From a longer-term production and market perspective, combining the continuous foaming line with rebonded foam production was better suited to the planned scale of the factory.

The project also included the required downstream cutting equipment. The CNC foam cutting machine was selected for shaped foam parts used in furniture and mattress products. Two circular foam cutting machines allowed multiple foam blocks to be sliced within the same cutting cycle, while the vertical foam cutting machine was mainly used for trimming block edges and carrying out straight cuts before further processing.

Based on the factory conditions, we also prepared a layout covering equipment placement, production flow, the connection between foaming and downstream processing, and operator working space. Through several video meetings, the client observed an actual flexible foam production process, including the operation of the continuous foaming line and its connection with downstream cutting and processing. The discussions also covered daily operation, practical differences between equipment designs, and the configurations suitable for this project.

The rebonded foam machine purchased by this client

Why the Client Finally Chose Us

The client compared proposals from several equipment suppliers before making the final decision. What distinguished Sabtech was not simply the ability to supply the required machines, but the client’s greater confidence in our communication, understanding of the project, and approach to developing the solution.

1. Responsive Communication with Clear Follow-Through
As the project developed, the client’s questions were answered promptly and directly. Details confirmed during earlier discussions were carried forward into the subsequent planning, allowing the project to progress from the initial inquiry to the final equipment plan without repeatedly revisiting the same issues.

2. Project-Specific Planning Rather Than a Standard Package
The proposed solution was developed around the client’s target products, factory conditions, existing foaming workers, and downstream processing requirements. The equipment plan and factory layout were connected to how the factory was expected to operate, rather than being presented as a standard equipment package.

3. Recommendations Grounded in Actual Foam Production

During several video meetings, the client observed an actual flexible foam production process and discussed daily operation, practical differences between equipment designs, and configuration choices.

After comparing the suppliers, the client had greater confidence in Sabtech’s overall understanding of the project and selected us for the complete equipment order.

Final Procurement Content

After confirming the plan, the client completed the purchase in May 2022. The procurement included:

one complete continuous foaming production line for producing virgin flexible PU foam used in furniture and mattress applications
one rebonded foam production line, including: rebonded foam machine, steam boiler, foam shredder machine for rebonded foam production
one CNC foam cutting machine for cutting shaped foam parts required by furniture and mattress products
two circular foam cutting machines for slicing multiple foam blocks in the same cutting cycle to reduce processing time
one vertical foam cutting machine for trimming foam block edges and carrying out straight cuts before further processing

Loading rebonded foam line

Loading continuous foam machine and foam cutting machine

Remote Installation and Production Startup

The equipment arrived at the client’s factory in July 2022. Because pandemic-related travel restrictions prevented our engineer from travelling to the site, installation and commissioning support were provided remotely. Commissioning was completed in October, and production started in November 2022.

After the initial setup entered production, the client later placed two additional orders to expand the factory’s downstream processing capacity and product applications. The subsequent development of the factory is covered in How a Saudi PU Foam Factory Expanded Beyond Its Initial Production Lines.

What Are the Two Stages and Web-Forming Methods for Making Polyurethane Filter Foam?

Manufacturing polyurethane filter foam typically involves two key stages. The first stage involves preparing open-cell or partially open-cell polyurethane foam according to the desired porosity. If the foam is closed-cell, it needs to be subjected to roller compression to rupture the cell walls, thereby creating the necessary porous structure. The second stage is to remove all the cell membranes to form a reticulated structure.

To produce polyurethane filter foam, the size of the pores and the structure of the network of the foam are largely determined by the catalyst, foaming agent, and surfactant.

In practical operations, there are two common methods for forming the network:

First is the alkali hydrolysis method. The steps of this method involve immersing the soft polyester-type polyurethane foam obtained from the first stage in a 10% sodium hydroxide solution at 50 degrees Celsius for about 10 minutes. Then it goes through processes such as washing with water, neutralization with acetic acid, another round of water washing, and drying, resulting in the final product of polyurethane filter foam.

Another method is the combustion method, also known as the explosion method. This method requires placing the soft polyether-type or polyester-type polyurethane foam obtained from the first stage into a sealed container. The container is then evacuated to 13.3 Pa, followed by the introduction of oxygen and natural gas (in a volumetric ratio of 2:1), bringing the internal pressure of the container to a certain level (which increases with the porosity). Next, the gas inside the container is ignited using a spark plug. The heat generated from the combustion process will burn off or melt the cell membranes without damaging the cell struts. Finally, the resulting product after combustion is cleared with air, and the filter foam is removed from the container.

Both of these methods are effective ways to prepare polyurethane filter foam, and the specific choice between them depends on the material of the foam and the desired structural characteristics.

PU Flexible Foam Combustion Performance, Grade, and Testing

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.

Comparison of Performance of A-1 and A-33 in Soft Polyurethane Foam Production

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.

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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.