خط إنتاج وسائد الإسفنج الذكي
UREXCEED polyurethane memory pillow production line delivers high-efficiency, customizable, and eco-friendly manufacturing solutions for premium memory foam pillows.
خط إنتاج وسائد الإسفنج الذكي
UREXCEED polyurethane memory pillow production line is designed for efficient and precise manufacturing of memory foam pillows, making it the ideal choice to meet modern market demands. This production line features advanced تقنية الرغوة ذات الضغط العالي، جنبًا إلى جنب مع تصميم القالب الدقيق وأنظمة التحكم الآلية، مما يضمن أن كل وسادة تقدم أداءً ممتازًا في ذاكرة الشكل وراحة فائقة.
تدفق عملية UREXCEED Pillow Production Line
PU Foam Pillow Product Process
الخطوة 1
الخطوة 2
الخطوة 3
الخطوة 4
الخطوة 5
Gel Pillow Product Process
الخطوة 1
الخطوة 2
الخطوة 3
الخطوة 4
الخطوة 5
الخطوة 6
الخطوة 7
نبذة عن UREXCEED خط إنتاج الوسائد الرغوية
UREXCEED offer a variety of customizable production lines, including carousel lines, rotary lines, and banana lines, designed to meet the specific needs of different manufacturing processes. Each production line type is engineered for maximum efficiency, flexibility, and scalability, enabling businesses to optimize their production while maintaining high-quality standards.
بغض النظر عن مدى تعقيد أو حجم احتياجات الإنتاج الخاصة بك، فإن UREXCEED® لدينا خط الإنتاج المناسب لك، مما يضمن أقصى قدر من الإنتاجية وأقل قدر من التوقف عن العمل. تم تصميم حلولنا الشاملة لتحسين الكفاءة وتقليل تكاليف التشغيل وتعزيز عملية التصنيع بشكل عام.
خط إنتاج الكاروسيل
مناسبة للإنتاج على نطاق صغير ومتوسط.
خط الإنتاج الدوار
مثالية للإنتاج المستمر ذو القدرة العالية.
خط إنتاج الموز
تُستخدم في العمليات التي تتطلب أوقات تبريد ممتدة.
ملخص الاختلافات
| خط الإنتاج | الميزة الرئيسية | الأفضل لـ | متطلبات المساحة | القدرة الإنتاجية |
|---|---|---|---|---|
| خط إنتاج الكاروسيل | قرص دوار مركزي | الإنتاج على نطاق صغير | قليل | قليل |
| خط الإنتاج الدوار | مسار دائري مستمر | إنتاج الزي الموحد على نطاق واسع | واسطة | عالي |
| خط سكة حديدية دوارة | نظام السكك الحديدية المضمنة في الأرضية | قوالب ثقيلة، إنتاج عالي القدرة | متوسط-عالي | عالي |
| خط إنتاج الموز | مسار منحني ممتد | عمليات المعالجة/التبريد الطويلة | عالي | متوسط-عالي |
توصية:
- خطوط قرصية أو دائرية:مناسبة لإنتاج وسائد إسفنجية قياسية ذات مساحة وميزانية معتدلة.
- خط سكة حديد دائري أرضي:مثالي للمصانع التي تركز على القوالب ذات السعة العالية أو الثقيلة.
- خط الموز:الأفضل للمنتجات المعقدة التي تتطلب أوقات معالجة أو تبريد ممتدة.
حل شامل من خط إنتاج الوسائد المصنوعة من رغوة البولي يوريثين
UREXCEED foam pillow production line one-stop service is designed to provide customers with a comprehensive solution, from raw material sourcing to equipment installation and commissioning, as well as mold customization and production line setup. UREXCEED supply high-quality polyurethane raw materials, ensuring the comfort and durability of the pillows, and provide advanced foam pillow production equipment, including ضغط عالي/آلات الرغوة ذات الضغط المنخفض, automated assembly lines, and more, helping you improve production efficiency and reduce labor costs. Additionally, UREXCEED custom mold services allow for the production of molds in various sizes and styles to meet customer needs, ensuring product accuracy and consistency. Through this complete one-stop service, we help clients simplify the procurement process, reduce production risks, and enhance market competitiveness.
آلة الرغوة
قالب
المواد الخام
Mold Temperature Control Machine
Punch Machine
Vacuum Bubble Crusher
Raw material system
- Isocyanate (MDI): a key reaction component that affects the support and rebound properties of the foam.
- Polyether Polyol: Determines the softness and viscoelasticity of foam, and is the main material for regulating softness and hardness.
- Water: Reacts with isocyanates to produce CO ¾ gas, forming a pore structure and controlling the foaming rate.
- Catalyst: Adjust the foaming reaction rate, control the initiation time and molding efficiency.
- Crosslinking agent: enhances the stability of the foam structure, improves pressure resistance and durability.
- Emulsifiers/Surfactants: Optimize pore uniformity to prevent defects such as collapse and poor foaming.
- Auxiliaries (optional): antioxidants, anti-yellowing agents, flame retardants, fragrances, color pastes, antibacterial additives, etc., can be customized according to the target market
| Pillow type | Shore hardness (A) | Applicable population | Feature Description |
| Soft pillow | 10–15 | Women/children | Soft fit, low rebound |
| Medium soft (universal type) | 15–22 | Mass consumer market | Support + Comfort Balance |
| Rigid brace type | 22–30 | Cervical Support/Men’s Market | Obvious support, high rebound |
- The softness and hardness range of the pillow can be flexibly adjusted by the type and ratio of polyether (such as Shore hardness A 10-30).
- Can provide environmentally friendly, low VOC formulas, support REACH/CertificPUR certification requirements
- Customized fragrances, densities, and skin feel for different end point markets (cross-border e-commerce, high-end home furnishings, offline channels)
- A/B component storage tank (200L × 2)
- Precision heating constant temperature system (temperature control range 20-25 ℃)
- Mixing device (to prevent sedimentation)
- Pipeline pressurized circulating feeding system (connecting foaming equipment)
آلة الرغوة
| Project | High Pressure Foaming Machine | Low Pressure Foaming Machine |
| Working principle | Components A and B are mixed by high-pressure impact without mechanical stirring | Components A and B are mixed by mechanical agitation in the mixing head |
| Working pressure | 120–200 bar | Atmospheric or low pressure (< 10 bar) |
| Injection method | Mechanical arm automatic feeding/fixed-point feeding system | Manual injection/Simple guide rail injection |
| Mixing uniformity | Very high, fine and uniform pores | Generally, there may be slight color differences or hardness fluctuations |
| Cleaning method | High-pressure self-cleaning, usually without solvent | Manual cleaning, using organic solvents |
| Product consistency | Excellent, suitable for high-standard products | Generally, it is greatly affected by manual operation |
| Automated adaptability | Highly compatible with automated production lines | Suitable for manual operation, limited automation capability |
| Equipment costs | Higher (about 1.5-2 times that of a low-voltage machine) | Low, suitable for small and medium-sized initial investments |
| Raw material adaptation requirements | Higher temperature and viscosity control requirements for raw materials | Strong adaptability to raw material conditions |
| Applicable scenarios | High-end brands/export orders/high-quality foam | Start-up factories/small batch production/markets with low labor costs |
| Advantages summary | Good mixing effect, no installation, easy to clean, high efficiency | Low cost, simple structure, easy maintenance |
| Summary of shortcomings | High investment costs and strict requirements for raw material conditions | Cleaning is cumbersome, and product consistency is slightly poor |
| Indicator | High pressure pu foam machine | Low pressure pu foam machine |
| Mixed mode | High speed impact | Mechanical stirring |
| Mixing uniformity | ★★★★★ | ★★★☆☆ |
| Cost inputs | عالي | Medium/Low |
| Adapt to automation | Support (recommended) | Basically not supported |
| Cleaning method | Self-cleaning | Solvent cleaning |
| Recommended yield | More than 1000 pieces/day | Less than 500 pieces/day |
- If your goal is to establish an automated and standardized plant, it is recommended to prioritize high-pressure systems.
- For customers with limited budgets or in the verification stage, they can start with low-voltage systems and upgrade later.
- We can recommend the most suitable foaming system solution based on your formula viscosity, daily production target, and operating team configuration.
Mold system
Mold material:
- Good thermal conductivity, fast heating, stable temperature control → shorten the foaming reaction and cool down, and improve production capacity
- Lightweight design for easy manual handling or automatic demolding and grabbing
- Surface treatment is smooth, supporting various surface processes such as mirror polishing/texture etching
- Strong corrosion resistance and resistance to polyurethane raw material erosion
- Long service life, up to 20-300,000 cycles on average
- Polished surface: suitable for soft touch pillows, simple appearance
- Corrosion imitation fabric: improve anti-slip performance, simulate fabric visual
- Mirror plating: used for high-end customization to enhance texture
Mould base:
The mold frame is used to support and fix the mold, which directly affects the opening and closing efficiency and operational safety of the mold. According to the degree of automation and production capacity requirements, the mold frame is mainly divided into the following categories.
- The opening and closing of the mold is completed by manually operating the mold frame handle or lever
- Simple structure, low cost, suitable for small batch or trial production
- The labor intensity is high, and the operator needs to have certain experience
2) Automatic opening and closing mold frame
- Using electric or hydraulic drive to achieve automatic opening and closing of the mold
- Improve production efficiency and reduce human error
- Adapt to automated production lines, support the use of robotic arms or gripping devices
3) Pneumatic auxiliary mold frame
- On the basis of manual opening and closing, a pneumatic power assist system is added
- Significantly reduce the labor intensity and difficulty of operators
- Suitable for factories with medium production capacity and the desire to save labor costs
Practical advice :
- If the target is the mid-to-high-end market, it is recommended to prioritize the use of etched or mirror-treated aluminum molds to enhance the appearance and texture of the product
- The recommended number of molds is 1.2 to 1.5 times the number of workstations to meet the needs of mold replacement, maintenance, and flexible production scheduling
- The mold needs to be used with a mold temperature machine to ensure the quality of foaming and setting time
Mold temperature machine
The mold temperature machine is an important equipment for adjusting the temperature of the mold. By circulating heating or cooling medium (usually hot oil or water), the mold is kept within the set constant temperature range to ensure uniform and stable chemical reactions during the foaming process.
Main functions and advantages:
- High temperature uniformity: avoid local overheating or overcooling of the mold, prevent uneven foaming, foaming defects or deformation of the product
- Shorten Foaming and Cooling Down: Accelerate curing speed, improve production rhythm and capacity
- Extend mold life: Constant temperature operation reduces thermal stress and avoids mold cracking or deformation
- Support multi-mold switching: set multi-stage temperature control through the program to meet the process requirements of different molds or products
Technical parameter reference:
- Temperature control range: common 30 ℃~ 150 ℃
- Temperature control accuracy: ± 1 ℃
- Heat medium: hot oil or circulating water (optional according to equipment scale and demand)
- Circulating flow and pressure: Ensure high-speed and uniform flow of heat medium, and respond quickly to temperature changes
Punching Machine (optional)
- Multiple punching methods: mechanical punching, pneumatic punching, or laser punching, choose the appropriate solution according to product requirements
- High degree of automation: supports automatic drilling on the assembly line, ensuring accurate and consistent drilling position and spacing
- Adapt to a variety of materials and hardness: can handle PU foam materials of different densities and thicknesses
- Energy saving and environmental protection: the equipment operates stably, has low noise, and meets industrial safety standards
- High-end soft pillow, improve breathability, reduce stuffiness
- Special function pillows, such as massage or healthcare pillows, optimize air circulation
- Customized products to meet customers’ personalized needs
- Determine whether punching equipment is needed based on product design and Market Positioning
- For brand factories pursuing differentiated competitiveness, punching equipment is an effective tool to enhance product added value
Breaking bubble machine (optional)
- Effectively breaking large bubbles: using high-speed rotating blades or ultrasonic technology to destroy large bubbles in the foam
- Improve pore uniformity: optimize the internal microstructure of foam and enhance the stability of physical properties
- Reduce defect rate: reduce quality problems such as fracture and deformation caused by irregular pores
- Improve product consistency: ensure stable product quality between batches
- Suitable for high-end pillow products with high requirements for foam fineness
- Flexible selection based on production line size and budget
Demoulding system
- Advantages: low equipment investment, flexible operation, suitable for small batch or multi-variety production
- Disadvantages: high labor intensity, low efficiency, susceptible to human factors, poor quality stability
- Advantages: Improve demoulding speed, reduce labor costs, improve product consistency and safety
- Suitable for medium and large automated production lines
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قائمة التشغيل
مراجعة جيدة لخط إنتاج الوسائد الذكية
UREXCEED Memory Foam Pillow Production Line has been widely praised by customers for its exceptional efficiency, precise molding capabilities, and reliable performance. With cutting-edge technology and customizable options, it delivers consistent quality while optimizing production processes. Customers highlight its ease of operation, durability, and ability to meet high market demands, making it an ideal solution for businesses aiming to enhance productivity and product quality.
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لقد غير خط إنتاج الوسائد المصنوعة من الإسفنج الذكي عملية التصنيع لدينا. الدقة في التشكيل والاتساق في الجودة استثنائيان. من السهل تشغيلها وصيانتها، وتجاوزت كفاءة الإنتاج توقعاتنا. موصى به للغاية!
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