Company Background: Founded in 2019, this specialized manufacturer focuses on producing acoustic and furniture foam materials. Their facility spans over 40,000 square meters and is located in Foshan, China.

Challenge: The client sought to fully automate their foam production line, from the initial foam formation process through to the cutting stage. Their main challenges included:

• Manual production processes that limited efficiency
• Space constraints due to structural pillars in the factory layout
• Need for both long and short foam production capabilities
• Requirements for precise cutting and immediate edge finishing

Solution:

We developed a comprehensive, customized foam production and processing solution that included several key components:

1. SR-HCF Horizontal Continuous Foam Production Line

• Highly efficient continuous foam production requiring only one hour of daily operation
• Equipped with a 50-meter conveyor system to accommodate both short and long foam production
• Significantly improved production capacity while maintaining quality

2. SR-SCC Foam Transport Clamp

• Automated handling system for transferring foam to curing and processing areas
• Reduced manual handling requirements and improved workplace safety

3. SR-CL Curved Conveyor Line

• Custom-designed solution to address factory layout constraints
• Innovative curved design bypassing structural pillars
• Maximized existing space utilization without requiring costly facility expansion
• Enhanced material flow to storage and processing areas

4. Dual SR-HT001 Rail-Mounted Horizontal Cutting Machines

• Capability to cut foam lengths up to 100 meters
• Simultaneous processing of both long and short foam sections
• High-precision cutting capabilities
• Integrated automatic edge-trimming functionality
• Eliminated additional processing steps by completing cutting and trimming in one operation

Results: The implemented solution achieved:

• Full automation of the foam production process
• Optimized space utilization despite structural constraints
• Reduced labor costs through integrated processing
• Improved production efficiency with single-step cutting and trimming
• Enhanced product quality through precise, automated processing
• Ready-to-ship finished products without additional processing requirement