FOAM MAKING MACHINE AND FOAM RECYCLING
Our solutions for foam blocks, shredded foam and rebonded foam
Foam, shredded foam and rebonded foam are gaining popularity in many sectors, especially in those of home textile and bedding. Therefore, for manufacturers in-house foam production dramatically enhances versatility, flexibility, and sustainability by enabling customization of block dimensions/shape, and personalized formulations to increase brand differentiation.
At the same time, the capability to produce foam variants such as shredded foam and rebonded foam in-house offers businesses a competitive edge by enhancing their operational agility and cost-effectiveness. On top of that, being able to create a new usable material from scraps allows you to save money and promote environmental good practices.
Let’s dive into the world of foam making and foam recycling and explore how these machines are reshaping industries.
The advantages of making foam and recycle foam in house are endless
Foam cost reduction
Up 30% cost reduction by producing foam blocks in house and only when needed
Zero transportation costs
Both for foam making (compared to buying blocks) and for foam scrap management, as you will be able to use the output as a new filling material
Supply chain shortening
Optimization of the supply chain, through a precise quality control, an increased operational flexibility and a significant reduction of total costs.
On all foam machines, the return on investment (ROI) is less than 12 months. However, these are not the sole advantages. Starting from the second operational year there is also a significant net cost reduction. This derives from different factors, including an increasing production efficiency, a reduction of transport and storage costs resulting from buying foam from external suppliers, and the possibility to optimize internal process to adapt to the industry’s specific needs.
Brighi Foam Solutions span from making foam blocks in discontinuous to foam shredding and rebonded foam making. This is on top of our solutions for foam pillows: foam punching, stuffing and complete lines for foam and latex.
FOAM SHREDDING
The versatility of shredded foam extends far beyond recycling applications. By blending shredded foam with other materials, such as fibers or textiles, businesses are able to combine the benefits and characteristics of different materials in one single filling material to create pillows and cushions that offer a balanced and tailored experience.
Shredded foam can then be repurposed for a multitude of applications and particularly
in the bedding industry as a new filling material for pillows and sacks or to create rebonded foam.
DISCOVER OUR FOAM SHREDDING MACHINE
SINGLE BLOCK FOAM-MAKING MACHINE
However, in the field of foam production, machines are only a part of the equation. Chemicals products and recipe management software are essential to optimize formulations and ensure product quality. That is why we developed Formula, our recipe creation and quality control software.
With Formula, companies will no longer need in-house chemists, as they can rely on the software to easily create recipes and make a scientific and efficient foam production. In addition, they will be able to track essential data such as density, speed and weight tolerance to achieve the highest levels of quality.
DISCOVER OUR SINGLE BLOCK FOAM MAKING MACHINE
REBONDED FOAM MAKING
Rebonded foam emerges as an evolution of polyurethane foam, catering to diverse industrial needs beyond conventional foam applications in the bedding industry: construction, sports flooring, automotive, footwear thanks to its excellent acoustic and thermal insulation properties.
The process of rebounding foam involves compressing shredded foam into a dense, resilient material, enhancing its durability and usability for a range of applications. This innovative approach not only reduces waste but alsoaddresses the demand for eco-friendly alternativesin the manufacturing landscape.
In the bedding industry, rebonded foam finds significant utility in mattress manufacturing. Renowned for its resilience and durability, rebonded foam serves as an ideal middle layer in mattresses,providing essential support and stability. Its ability to withstand prolonged use without sagging makes it a preferred choice for enhancing mattress longevity and ensuring consistent comfort and support throughout its lifespan.
DISCOVER THE FULL CONFIGURATION OF OUR REBONDED FOAM LINE
FOAM TYPES
FOAM BLOCKS
Foam can be created in many different ways by mixing chemicals (polyols and isocyanate): with continuous foam lines, with high pressure lines and in discontinuous. Our solutions, the discontinuous low-pressure line, creates open cell foam, which is ideal in the bedding sector to make pillows and cushions because of its excellent breathability.
SPAGHETTI FOAM
Spaghetti foam are usually the byproduct of another process, foam punching. These slender, elongated pieces of foam can either be used directly or shredded into smaller pieces to make a new filling material for pillows and other soft items.
SHREDDED FOAM
This material consists of small, irregularly shaped pieces of foam obtained by shredding larger foam blocks or scraps. Shredded foam is commonly used as filling material in pillows, cushions, and bean bags due to its ability to conform to different shapes and provide comfort.
REBONDED FOAM
Made from recycled foam scraps, rebonded foam blocks are dense and resilient materials used primarily as support layers in mattresses and furniture. They offer durability and long-lasting support, making them an eco-friendly choice for various applications requiring stability and comfort.
Fill out the form to receive a customized consultation, and together we will find the right solution for your needs.
FAQ
Foam making machines operate by mixing air, liquid, and chemicals (isocyanate and polyols) to produce foam. The mixture is agitated to distribute the bubbles evenly, resulting in a lightweight and stable foam.
Foam making machines find applications across a diverse range of industries, including automotive manufacturing, bedding, construction, packaging and aerospace.
Absolutely! Foam making machines are incredibly versatile and can produce a wide range of foam types, from rigid insulation foam to soft cushioning foam.
Yes, indeed! With advancements in technology and growing demand for sustainable materials, foam recycling has become increasingly economically viable.
