FOAM PRODUCTION

Advanced Foam Production Solutions by Fincorp Est- Precision & Quality

FM - CONTINUOUS FOAMING MACHINE

The Optimal Solution for Enhanced Foam Quality. This machine represents a leap in foam production technology, offering precise calcium carbonate integration for superior foam consistency.

The FM Foaming Machine is ingeniously designed for high-capacity foam production, with an output range of 150 to 250 kg per minute. This capability allows for the creation of large foam blocks, achieving dimensions up to 2080 mm in width and 1250 mm in height, variable based on the selected density. A notable feature of the FM-150 is its square Flat-top and straight sides, which significantly reduce waste percentages to around 5-6 percent. This efficiency is a marked improvement over traditional domed foaming plants.

The machine's design ensures minimal density variation within each block, resulting in a thin outer skin with fewer hard points. This characteristic greatly reduces the need for trimming, enhancing overall efficiency. The FM is specifically tailored for continuous production of flexible polyurethane foam in rectangular blocks, featuring a flat top configuration. It operates on a low-pressure system, equipped with multiple mixer inlets and re-circulation for optimum mixing. The catalyst metering system includes three main streams as standard, with auxiliary options for additional streams, colors, or catalysts.

Furthermore, the FM contains a closed foaming tunnel with a manually (or motorized) adjustable fall-plate system, sidewalls, and a conveyor with infinitely variable speed, ensuring precise control over the foaming process.

While the above specifications represent the standard model, Fincorp offers customization to meet specific requirements. Most machines are tailor-made to suit individual customer needs and budget constraints. The FM-150 is also designed with simplicity in mind, making it suitable for operation in regions where skilled technicians might not be readily available.

The FM is engineered with a high shear pin design mixing head, ensuring efficient and thorough blending of materials. This mixer is powered by a suitably sized motor, with the ability to adjust mixer speeds through interchangeable pulleys. For precise control, the mix head includes a manifold mounted three-way ball valve with durable Teflon seals, allowing for efficient operation and easy maintenance.

Designed for robustness, the mix head is securely mounted on its own chassis, enhancing stability and durability. Additionally, the mixer seal chamber benefits from lubrication via the polyol stream, effectively preventing chemical leakage to the seal and ensuring the machine's longevity.

For added versatility, a Variable Speed Drive can be provided as an optional extra, offering greater control over the mixing process. In the event of any operational issues, the machine is designed to automatically halt all streams and the mixer, ensuring safety and preventing potential damage.

The FM's pumping system is designed for precision and efficiency. It features gear pumps with variable frequency drives for all liquid components, except water and Methylene Chloride (M/C), which use piston positive displacement pumps. This system includes a re-circulation mechanism for consistent material delivery.

A precision needle valve on the pneumatic control panel accurately meters Nucleating Air, ensuring independence from mixing head pressure. The machine also allows for optional independent color metering streams.

Equipped with a comprehensive control system, the FM oversees the operation of various pumps and mechanical components. Customers are responsible for providing on-site piping for Polyol, T.D.I., and Methylene Chloride inlet and return connections to the mixing head.

Flow meters are included for T.D.I., water, MCL, and air, along with stainless steel tanks for Water, Silicone, Stannous Octoate, and Amine, ensuring precise measurement and safe storage of these components.

The FM is equipped with an efficiently designed foaming tunnel that fully encloses the foam slab. It features top cover plates and sidewalls, creating a controlled environment for foam production. The tunnel's floor comprises a horizontal track-type conveyor, outfitted with durable aluminum slats, ensuring smooth movement of the foam.

The roof of the tunnel extends across the full width of the conveyor, enhancing the enclosure. To facilitate access to the foam and provide adequate ventilation, flexible curtains are installed. A roller conveyor is strategically placed at the tunnel's end to seamlessly transfer the foam block to the block cut-off machine.

Ventilation is a key aspect of this design, with two axial fans incorporated into the roof. Customers are responsible for providing and installing the necessary ducting for these fans on-site. Additionally, ventilation above the Block Cut-off machine is advised. An optional Infra-Red Heater unit can be included to reduce the curing time of the block surface, further enhancing the machine's efficiency.

The conveyor is powered by a gear reduction motor, complete with a variable speed controller, push button control, and a digital speed indicator for precise operation. The sidewalls of the tunnel are constructed from either laminated plywood or steel plates, offering robustness and stability to the entire structure.

In the FM, the transition of chemicals from the mixer is smoothly facilitated through a trough leading to a paper-covered Fall-plate. This unique design is instrumental in enabling the production of flat-topped foam blocks. The Fall-plate system is composed of interconnected plates, each featuring its own height adjustment capability. This adaptability is further extended to both the Trough and Fall-plate, which are height-adjustable to accommodate varying foam formulations. This system's flexibility ensures consistent quality across different types of foam products.

For the FM, an appropriate curing area is vital to the foam production process. This area should ideally be located outdoors or in a well-ventilated indoor space. Its size must align with the machine's production capacity to ensure efficient handling of output. A concrete floor is recommended to facilitate the movement and prevent damage to rolling carts, which are to be provided by the customer. After production, the foam requires a curing period of 8 hours before it can be transferred to the cutting or storage area, a crucial step to ensure optimal foam quality.

RS System:

The FM is equipped with an innovative RS (Round top Scrap reduction) system, aimed at reducing the scrap produced by the foam's round top and corners. This is achieved through the use of a PE (Polyethylene) film along the side walls. The RS system cleverly lifts the PE film, mitigating corner deformations caused by the friction of the rising foam.

Flat Top System:

Working in conjunction with the RS system, the FM's Flat Top System is instrumental in refining the foam blocks' quality. This system eliminates irregularities on the top surface of the foam block, ensuring each block has flat tops and square edges. The result is a consistently uniform and high-quality foam product, enhancing the overall efficiency of the foaming process.

Fincorp offers a complete range of ancillary equipment to complement the FM-150 foaming machine. This includes essential tanks for Polyol, TDI, and M/C, ensuring that all components needed for efficient foaming are readily available. While it's common for customers to source these tanks locally, Fincorp can provide them as part of a complete solution if required.

In recent years, the use of Calcium carbonate as a filler has gained popularity. Responding to this trend, Fincorp has developed specialized equipment to effectively mix and pump Calcium carbonate-filled polyol. This typically involves a Pre-Mixer (our Turbo-mixer) and a dedicated day tank, with a separate stream leading to the mix head. These additions are designed to seamlessly integrate with the FM-150, enhancing its functionality and versatility in foam production.

The tunnel's design encloses the foam slab fully, with top plates and sidewalls, and uses a horizontal conveyor with aluminum slats for movement. A roof covering the conveyor and flexible curtains allow foam access and ensure ventilation. At the tunnel's end, a roller conveyor moves the foam to a cutting machine. Two axial fans in the roof require customer-provided ducting for ventilation, which is crucial above the cutting machine. An optional Infra-Red Heater can reduce surface curing time. The system includes a gear motor with variable speed control and digital indication, with sidewalls made of laminated plywood or steel.

The FM is equipped with a sophisticated 3-paper system, designed for seamless integration with the foam production process. The bottom paper feed reel, a crucial component of this system, is strategically positioned in front of the foaming platform. This reel is outfitted with features for alignment and tension adjustment, ensuring smooth operation and precise paper placement.

Additionally, the system includes side paper feed reels, located on both sides of the tunnel entrance. These reels are also fitted with tension adjustment mechanisms, allowing for consistent paper feed and tension control. At the tunnel's end, the side papers are rewound around a pair of capstan rollers. This rewinding process is ingeniously designed to be self-adjusting, synchronizing its speed with the foaming speed, thus maintaining a consistent and efficient operation throughout the foaming cycle.

DBF - AUTOMATIC DISCONTINUOUS BLOCK FOAMING MACHINE

Developed with insights from Spuhl AG of St.Gallen, Switzerland, the original designers, this machine is a testament to our commitment to excellence. Fincorp Est. has meticulously refined both the production process and the machine, enhancing its performance to meet the highest standards of quality and reliability.

Fincorp Est - Discontinuous Foaming Machine

The DBF is engineered to handle a variety of foam types, including Flexible and Rigid PU foam, HR, and Memory foam with densities up to 80 Kg./cu.m. It is perfectly suited for producing high-quality foam for the Furniture, Bedding, and other related industries.

At the heart of the DBF's operation is the efficient mixing of essential chemical ingredients - Polyol, TDI, Amine, Silicone, Water, Tin, and Methylene Chloride for low-density foam. These components are delivered to a mixing chamber through highly accurate metering systems, ensuring the perfect ratio for each batch. The mixed chemicals are then dispensed into a standard-supplied Rectangular Block Mould.

In the mould, a rapid chemical reaction transforms the liquid mixture into a cream that expands, filling the mould to form a full-sized foam block. The final product's size and shape are determined by the mould's dimensions, showcasing the machine's precision and adaptability in foam production.

The standard DBF model boasts an initial capacity of 120 Liters (150 Kg.) and is equipped with a weight system and advanced computer control system for precise operations. Enhanced user interaction is facilitated through a touch screen interface, complemented by a high-accuracy dual weigh system for optimal precision.

Customization is key, as the moulds can be tailored to various sizes to meet specific customer requirements. Additionally, the machine includes a water flush system and a vacuum filling system, providing a comprehensive package. This all-in-one machine is ready for immediate production upon delivery, embodying efficiency and convenience.

Cost-Efficiency: The DBF stands out for its affordability, both in terms of low initial price and minimal installation costs, making it an economically sound choice for businesses.

Precise Chemical Utilization: The machine's accurate pumps and straightforward controls ensure economic utilization of chemicals, contributing to cost savings and consistent product quality.

Versatility in Density Production: With the capability to produce a wide range of foam densities, the DBF offers unparalleled flexibility in meeting various industry needs.

Space-Saving Design: The machine's compact and robust design requires minimal factory space, making it an ideal solution for facilities with space constraints.

Ease of Operation: Its simple operation demands minimal training, ensuring a smooth and efficient production process with less downtime.

High-Quality Components: The DBF incorporates top-tier European components, including Festo Germany Pneumatics, Schneider France Electric, Omal Italy Valves, and Delta Controls from Taiwan, ensuring reliability and extended machine life.

Ready for Immediate Start-Up: The machine is supplied complete, guaranteeing immediate startup and swift integration into production lines.

Fincorp Est - Semi Automatic Discontinuous Foaming Machine

DBF - SEMI AUTOMATIC DISCONTINUOUS BLOCK FOAMING MACHINE

Whether for small, medium, or large-scale foam production, each model of the DBF-Semi is designed to meet the specific needs of various segments within the foam manufacturing industry, delivering precision, efficiency, and quality in every batch.

The DBF-Semi is renowned for its straightforward design, catering to a wide array of customers. It is a perfect fit for markets seeking durable, easy-to-maintain, and cost-effective machinery. Additionally, it serves larger foam producers with its capability to develop unique formulations or produce specialized, small-batch foams.

The DBF Semi-Automatic Discontinuous Block Machine (DBF-Semi) is offered in three distinct models to cater to varying production needs: the MMX 75, MMX 100, and MMX 150. Each model is tailored to deliver optimal performance with specific capacities and motor sizes, ensuring a perfect match for different operational scales.

MMX 75 Model: This model is equipped with a 5 HP motor, making it highly efficient for smaller-scale operations. It has a maximum capacity of 75 Kg, ideal for businesses that require a compact but powerful solution for foam production.

MMX 100 Model: Stepping up in capacity, the MMX 100 features a 7.5 HP motor, providing a balance of power and size. With a maximum capacity of 100 Kg, it's perfect for medium-scale foam production needs, offering increased output without sacrificing space efficiency.

MMX 150 Model: For larger-scale operations, the MMX 150 is the ideal choice. It comes with a robust 10 HP motor and can handle up to 150 Kg, making it suitable for high-volume foam production.

All three models require an air supply of 6 Bars, ensuring consistent performance and reliability across the range. Whether for small, medium, or large-scale foam production, each model of the DBF-Semi is designed to meet the specific needs of various segments within the foam manufacturing industry, delivering precision, efficiency, and quality in every batch.

CCU - CALCIUM CARBONATE UNIT

The Optimal Solution for Enhanced Foam Quality. This machine represents a leap in foam production technology, offering precise calcium carbonate integration for superior foam consistency.

The CCU ensures efficient handling of calcium carbonate, beginning with the loading of the powder into the tank via a precision powder feeder that uniformly meters in the material. Following this, polyol is pumped into the mixer. The high-speed special shear mixer is key to the process, transforming the mix into a homogeneous blend, essential for producing excellent quality foam.

Fincorp offers two models of the CCU - a 600-liter version and a larger 1500-liter variant, catering to different scale requirements. The mixer is designed to work in tandem with an agitated storage tank, which is essential for both storage and temperature adjustment of the mixture.

Fincorp also offers the storage tank, complete with an internal mixer and re-circulating pump, as part of a package deal. The 600-liter model, in particular, is ideally suited for box foaming applications, with powder feeding facilitated manually through a hopper.

FOAM PRODUCTION

FM - CONTINUOUS FOAMING MACHINE

DBF - AUTOMATIC DISCONTINUOUS BLOCK FOAMING MACHINE

DBF - SEMI AUTOMATIC DISCONTINUOUS BLOCK FOAMING MACHINE

CCU - CALCIUM CARBONATE UNIT

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