SKUM MODEL MBFM- I FOR THE MANUFACTURE OF BONDED FOAM FROM FLEXIBLE POLYURETHANE FOAM GRANULES.

With the constant development of Polyurethane Foam Industry in India, the trend for Bonded Foam is now picking up, and Foam Manufacturers have "better-late-than-never," realised an economical mode of converting waste foam and trimmings into a fantastic new product, which has better resilience and higher density, than the normal Flexible Polyurethane Foam.

In most Middle-East Countries, Bonded Foam is the only product that has been found to be most suitable for floor seating arrangement and as it is customary in certain Countries of the World to sit on the floor, the Bonded Foam has received a very special place. Since this product is in such good demand, it has been found affordable to granulate even good foam into granules to produce Bonded Foam.

It is therefore clearly understood, that Bonded Foam is not a Waste Product, but a Bi-Product of Flexible Polyurethane Foam.

PROCESS

The process involves, mixing of foam granules with fresh chemicals and filling up moulds and steaming it to allow the fresh foam to act as glue, and bond the granules. Bonded Foam can be manufactured in a density range from 40-200 Kgs./M³. There is no waste in the production of Bonded Foam, as it is manufactured in a rectangular flat topped shape, in sizes that suit most end-products. Trimmings of Bonded Foam can be re-granulated and re-used for production of Bonded Foam.

SYSTEM

The SKUM Model MBFM-I, comprises mainly of a mixing chamber with two hydraulically operated screw agitators, a pre-polymer spraying system, a mould filling and pressing system, a steaming system and a de-moulding station.

The MBFM-IA, has a separate weight box with load cells above the mixing chamber, so that the granulated foam can be transported in it to the required weight, while the mixing chamber is processing one batch of Bonded Foam Block. This system enables to increase the production capacity of the plant by 50% as compared to MBFM-I.

The MBFM-II model, has two press stations instead of one, besides the weight box with load cells, thereby giving an increase of 100% in production capacity, compared to MBFM-I.

TECHNICAL SPECIFICATIONS

Standard Equipment:

• Platform Scale with box for weighing of Foam Waste.
• Granulating Machine for Flexible Polyurethane Foam SKUM Model MGM-30.
• Granule and Polymer Mixer with two reversible Hydraulic powered Screw Agitators with filter top for foam dust extraction.
• Pre-polymer drum heater with thermostat control.
• Polymer metering system with feed pump, pressure gauge, control valve and dozing timer.
• MobileBlock Mould with steam dispersing system at bottom, two parted side walls and top plate.
• Hydraulic Piston Actuated Block Press with adjustable pressing height.
• Hydraulic Piston operated, mould steam coupling with steam valve and dozing timer.
• Hydraulic Power Pack with pressure gauge and solonoid control valves.
• Work Platform with Control Panel for hydraulic and electric functions.
• Jib crane, with special block grip for de-moulding of blocks.

MBFM - I :

Mould dimension Standard : 2070 X 1070 X 1000 mm.

Block dimension Trimmed : 2000 X 1000 X H mm. (max. ht. 600 mm.)

Block Capacity : app. 4 - 5 blocks/hr.

OPTIONAL EQUIMPENT

• Mould with different dimensions for final block size
                                       1) 2000 X 1500 X H mm.
                                       2) 2000 X 1200 X H mm.
                                       3) 2200 X 1200 X H mm.
• Steam dispersion system in top plate.
• Fume extraction system at mould filling and block press.
• Electrical Jib Crane with special block grip.
• Low pressure steam boiler.
• Extra drum heater for pre-polymer.
• Foam granulating machine, with granule storage silo.
• Granule extraction system with fan blower for conveyance of foam granules.