Dây chuyền sản xuất gối Memory Foam

UREXCEED polyurethane memory pillow production line delivers high-efficiency, customizable, and eco-friendly manufacturing solutions for premium memory foam pillows.

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Giải pháp một cửa

Từ việc cung cấp nguyên liệu thô đến thiết bị, khuôn mẫu và thiết lập dây chuyền sản xuất, UREXCEED cung cấp các dịch vụ trọn gói, đơn giản hóa việc mua sắm và phối hợp để giúp khách hàng đạt được sản xuất nhanh chóng.

Chất lượng cao và tùy chỉnh

UREXCEED cung cấp nguyên liệu thô cao cấp, thiết bị tiên tiến và khuôn mẫu chính xác, hỗ trợ sản xuất nhiều thông số kỹ thuật và tính năng gối khác nhau. Các giải pháp phù hợp đảm bảo tính nhất quán của sản phẩm và khả năng cạnh tranh trên thị trường.

Sản xuất hiệu quả và hỗ trợ chuyên nghiệp

Thiết bị tự động hóa UREXCEED nâng cao hiệu quả và giảm chi phí, trong khi hỗ trợ kỹ thuật chuyên môn, lắp đặt, vận hành và dịch vụ sau bán hàng nhanh chóng đảm bảo hoạt động sản xuất diễn ra suôn sẻ.

Dây chuyền sản xuất gối Memory Foam

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 công nghệ tạo bọt áp suất cao, kết hợp với thiết kế khuôn mẫu chính xác và hệ thống điều khiển tự động, đảm bảo mỗi chiếc gối đều có hiệu suất ghi nhớ hình dạng tuyệt vời và sự thoải mái vượt trội.

Quy trình hoạt động của UREXCEED Pillow Production Line

PU Foam Pillow Product Process

Bước 1

Mold Heating：The mold temperature controller is used to preheat the seat mold to the required temperature. This ensures proper material flow, uniform foaming, and improved product quality.

Bước 2

Spraying Release Agent：A release agent is evenly sprayed onto the heated mold surface to prevent the polyurethane material from sticking to the mold, ensuring easy demolding and a smooth surface finish.

Bước 3

Injecting Raw Materials: The high-pressure polyurethane foaming machine precisely mixes and injects polyether polyol (A-component) and isocyanate (B-component) into the mold cavity, ensuring uniform mixing and material distribution.

Bước 4

Closing the Mold and Foaming Process:The mold is closed, allowing the polyurethane material to expand and cure inside the cavity, forming the basic shape of the seat.

Bước 5

Demolding the Finished Product: Once the material has fully cured, the mold is opened, and the finished seat is carefully removed. At this stage, the seat is fully formed and can undergo further processing, such as trimming and upholstery.

Gel Pillow Product Process

Bước 1

Mold Heating：The mold temperature controller is used to preheat the seat mold to the required temperature. This ensures proper material flow, uniform foaming, and improved product quality.

Bước 2

Laying TPU Film：Evenly spread the TPU film in the gel mold so that it fits the mold surface, providing a protective layer for subsequent gel pouring while improving the durability and comfort of the finished product.

Bước 3

Pouring gel material:Pour the well-proportioned gel material into the mold covered with TPU film, so that it evenly fills the entire mold. Let it stand and wait for the gel to solidify, ensuring that the shape is stable and a uniform gel layer is formed.

Bước 4

Transferring TPU film and gel layer:Take out the cured gel layer together with the TPU film and carefully place it into the pillow mold, ensuring that it is positioned accurately so that it can be tightly combined with the memory foam or PU foam material.

Bước 5

Injecting Foam Materials: The high-pressure polyurethane foaming machine precisely mixes and injects polyether polyol (A-component) and isocyanate (B-component) into the mold cavity, ensuring uniform mixing and material distribution.

Bước 6

Closing the Mold and Foaming Process:The mold is closed, allowing the polyurethane material to expand and cure inside the cavity, forming the basic shape of the seat.

Bước 7

Giới thiệu về UREXCEED Dây chuyền sản xuất gối xốp

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.

Bất kể nhu cầu sản xuất của bạn phức tạp hay quy mô như thế nào, UREXCEED^® có đúng dòng sản phẩm dành cho bạn, đảm bảo năng suất tối đa và thời gian chết tối thiểu. Các giải pháp toàn diện của chúng tôi được thiết kế để cải thiện hiệu quả, giảm chi phí vận hành và nâng cao quy trình sản xuất tổng thể.

Tóm tắt sự khác biệt

Dây chuyền sản xuất	Tính năng chính	Tốt nhất cho	Yêu cầu về không gian	Năng lực sản xuất
Dây chuyền sản xuất Carousel	Đĩa quay tập trung	Sản xuất quy mô nhỏ	Thấp	Thấp
Dây chuyền sản xuất quay	Đường tròn liên tục	Sản xuất đồng phục số lượng lớn	Trung bình	Cao
Đường ray quay mặt đất	Hệ thống ray nhúng sàn	Khuôn mẫu nặng, sản xuất công suất cao	Trung bình-Cao	Cao
Dây chuyền sản xuất chuối	Đường cong mở rộng	Quá trình làm mát/bảo dưỡng lâu dài	Cao	Trung bình-Cao

Sự giới thiệu:

Đường tròn hoặc đường đĩa: Phù hợp cho sản xuất gối mút hoạt tính tiêu chuẩn có không gian và ngân sách vừa phải.
Đường ray tròn mặt đất: Thích hợp cho các nhà máy tập trung vào khuôn mẫu có công suất lớn hoặc nặng.
Dòng chuối: Thích hợp nhất cho các sản phẩm phức tạp đòi hỏi thời gian bảo dưỡng hoặc làm mát kéo dài.

Giải pháp một cửa Dây chuyền sản xuất gối mút PU

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 áp suất cao/máy tạo bọt áp suất thấp, 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.

Máy tạo bọt

Hơn

Khuôn

Hơn

Nguyên liệu thô

Hơn

Mold Temperature Control Machine

Hơn

Punch Machine

Hơn

Vacuum Bubble Crusher

Hơn

Raw material system

In the production process of polyurethane foam pillows, the selection and ratio of raw materials are one of the core factors that determine the “softness, hardness, resilience, odor, and durability” of the finished product. We will provide customized raw material solutions based on the specific needs of customers (such as softness level, target market, and skin feel requirements).

Core raw material composition:

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

Common hardness indicators (Shore hardness) reference:

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

Raw material characteristics and customization suggestions:

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)

Recommended configuration for raw material supply system:

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)

Máy tạo bọt

Các máy tạo bọt is the core of the foam pillow production line, responsible for accurately measuring, mixing, and evenly injecting A/B component raw materials into the mold. The equipment types are mainly divided into two categories: máy tạo bọt áp suất cao Và máy tạo bọt áp suất thấp. Different equipment directly affects product quality, production efficiency, and maintenance costs.

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

Comparison of two foaming machines:

Indicator	High pressure pu foam machine	Low pressure pu foam machine
Mixed mode	High speed impact	Mechanical stirring
Mixing uniformity	★★★★★	★★★☆☆
Cost inputs	Cao	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

Practical advice:

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

The mold is the direct carrier of foam pillow molding, which determines the dimensional accuracy, texture details, and demoulding efficiency of the finished product. A high-quality mold system not only affects the aesthetics of the product, but also relates to production rhythm, equipment life, and worker labor intensity.

Mold material:

Mainly aluminum alloy, taking into account độ dẫn nhiệt and service life.

We recommend using aluminum alloy as the main material of the mold for the following reasons:

Thuận lợi:

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

Optional mold surface treatment:

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 key to ensuring mold stability and ease of operation
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.

1) Manual opening and closing mold frame

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)

In the production process of polyurethane foam pillows, some products need to improve their breathability and softness through punching technology to enhance the user’s sleep experience. The punching equipment achieves customized product functions by precisely controlling the aperture, depth, and distribution.

Main features:

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

Application scenarios:

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

Optional suggestion:

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)

The bubble breaker is mainly used to eliminate coarse bubbles or uneven pores generated during the foaming process, ensuring that the internal structure of the polyurethane foam pillow is fine and uniform, improving softness and resilience, thereby enhancing the user experience.

Main functions and advantages:

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

Application suggestion:

Suitable for high-end pillow products with high requirements for foam fineness
Flexible selection based on production line size and budget

Demoulding system

Demoulding is the process of removing the finished product from the mold after the foam pillow is formed. Demoulding efficiency and safety directly affect the production rhythm and product quality.

Demoulding methods are mainly divided into two categories:

1) Manual demolding: relying on the operator to manually open the mold and remove the finished product

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

2) Automatic grasping equipment: used in conjunction with automatic opening and closing mold frames and robotic arms, demoulding is completed through mechanical grasping devices

Advantages: Improve demoulding speed, reduce labor costs, improve product consistency and safety
Suitable for medium and large automated production lines

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