Mountains of cushion off-cuts eat warehouse space and rack up disposal fees. You need a smart way to turn that trash into fresh blocks of usable foam—ideally without hiring a chemistry PhD. Enter the rebond foam machine, and more specifically, the SA-9A model, a tidy workhorse built to grind polyurethane scraps, glue them, and press them into new, revenue-ready sheets. Choosing an SA-9A rebond foam machine means:

• Zero landfill costs for PU waste.
• Fresh rebond blocks in under ten minutes.
• Adjustable density from 60 kg/m³ to 200 kg/m³.
• One-button recipe storage for different products.
• CE-marked safety shields for worry-free night shifts.

Stick around as we pull back the covers on how the system works, why recyclers love it, eight key performance angles, and a final checklist to judge if the SA-9A rebond foam machine belongs on your factory floor.

How The SA-9A Rebond Foam Machine Turns Scraps Into Gold

The SA-9A starts by shredding off-cuts into popcorn-sized flakes, mixes them with measured adhesive, loads the blend into a mold box, and then presses everything under steam-heated platens. Cycle time averages eight minutes, and each block emerges fully cured, ready for slicing. A color-touch screen stores fifty recipes, so operators swap densities with a finger tap. Sensors track temperature and pressure, shutting down automatically if limits are exceeded. Because the rebond foam machine runs on a sealed loop, VOC emissions stay below 20 mg/m³—well under EU guidelines. In short, the SA-9A delivers consistent, high-quality rebond without fuss or fumes.

Feeding And Grinding

Foam trimmings ride a conveyor into twin rotary blades that chew everything down to 10 mm chips. A cyclone pulls stray dust into a filter bag, keeping the shop floor spotless. Throughput tops 120 kg per hour, matching medium-size upholstery lines even on busy Mondays.

Blending With Adhesive

A spiral agitator tumbles chips while spraying water-based MDI glue. Load cells under the drum verify mix ratios to within 0.5 %. Uniform coating means the final rebond block has no weak pockets or crumbly edges, slashing customer complaints and warranty returns.

Pressing And Curing

The coated mix drops into a 2 m-long mold. Hydraulic rams press to the target density, set in kilograms per cubic meter via the HMI. Heated platens speed polymer cross-linking, so blocks exit firm, dimensionally stable, and cool enough to saw within an hour.

Environmental Payback And Landfill Relief

Every ton of PU you divert from landfill chops roughly 1.8 tons of CO₂ emissions, according to EU Life Cycle studies. By installing an SA-9A rebond foam machine, a mattress plant sending five tons of waste monthly can offset its carbon footprint equal to 400 trees per year. Disposal fees of $90 per ton vanish, turning cost centers into product lines—carpet underlay, gym mats, or acoustic panels. Add energy-saving steam-recapture loops and you’ll shave another 15 % off utility bills. The climate math looks so good that several regions now hand out tax credits for on-site rebonding gear.

Info: Check local grants—many eco-funds cover up to 30 % of equipment costs for PU recycling projects.

Key Features Operators Brag About Daily

Touch-screen simplicity keeps training under two hours. Color-coded hoppers prevent density mix-ups, while remote diagnostics let technicians tweak PLC settings from a laptop. The rebond foam machine also stores maintenance timers; it flashes reminders for blade sharpening and filter swaps, cutting unplanned downtime by half. Safety gates use coded magnets, so bypass tricks won’t fool the interlocks—insurance inspectors love that. Finally, an oversized hydraulic accumulator smooths ram motion, yielding uniform density even when chip moisture shifts with the seasons.

Quick Tip: Save recipe backups to a USB stick monthly—recovering settings after a power glitch takes seconds.

Safety And Maintenance: Keep It Running, Keep It Safe

Daily tasks: sweep chip bins, check glue level, and wipe photo-eyes clean. Weekly: grease ram rods and inspect hose crimps. Quarterly: calibrate load cells and replace cyclone filter socks. The SA-9A ships with a smart lock-out tag-out kit, so electricians isolate circuits before crawling behind panels. An on-screen logbook tracks every service step, satisfying ISO 45001 auditors. Fire risk? Minimal. The glue is waterborne, and the press chamber includes a built-in mist line to quench sparks. Follow the checklist and your rebond foam machine hums for 20 years.

Danger: Never override the platen-temperature alarm; overheated blocks can scorch and clog saw blades.

SA-9A Versus Competing Models

Fact: Faster cycles mean a single SA-9A can out-produce two older machines, trimming labor by 40 %.

Integrating The SA-9A Into Existing Lines

Drop-in installation takes two days. Position the grinder next to your foam saw table, bolt the press frame to the floor, and connect 380 V three-phase along with steam and air. The HMI can link to MES software, exporting batch IDs so each block’s genealogy shows up on packing labels. For plants running night shifts, an optional auto-stacker slides cured blocks onto pallets without human muscle. Because the rebond foam machine sits on vibration isolators, it won’t rattle neighboring lamination stations.

Suggestion: Install a small overhead camera; remote managers can verify block quality in real time.

Quality Control And Testing Standards

Every block passes through a roller conveyor with laser height gauges. Density samples are cored at three points and weighed on an OIML-class scale. Compression tests follow ASTM D3574, confirming rebound resilience above 35 %. The SA-9A’s PLC logs all readings, flagging trends before they drift out of spec. Customers receive a PDF certificate automatically—no clipboard scanning. By embedding QC inside the rebond foam machine workflow, you slash returns and build a “green yet reliable” reputation.

Warnings: Skipping weekly density probes can hide glue-mix errors that surface as crumbling panels months later.

Case Study: Mattress Factory ROI In Twelve Months

DreamRest Bedding sends 60 tons of trim to the landfill yearly. After installing an SA-9A rebond foam machine, they now convert scraps into high-density perimeter rails for hybrid mattresses. Added revenue: $150000 per year. Landfill savings: $5400. Net power and glue costs: $28000. Machine payment period? Eleven months flat. Operators praise the recipe recall button—density changes on the fly, so switching from rail stock to yoga-mat billets fits inside a lunch break. The plant also won a regional sustainability award, boosting brand appeal with eco-minded shoppers.

Future Upgrades And Smart-Factory Links

The manufacturer plans a cloud dashboard for real-time OEE stats. Vibration sensors on the grinder motor will predict bearing wear days before failure, texting the maintenance crew automatically. A color-chip doser is in beta testing, letting the rebond foam machine stripe blocks for easy grade identification. Finally, firmware 2.0 will support OPC UA, making integration with Industry 4.0 gateways painless—no more clunky serial converters or handwritten shift logs.

Conclusion

Choosing the SA-9A rebond foam machine turns polyurethane waste from a headache into a hero. You gain landfill relief, predictable density control, fast recipe swaps, and audit-ready data, all wrapped in a safety-first design. Eight performance pillars—throughput, payback, maintenance ease, safety, integration, QC, ROI, and future-proofing—prove their worth for factories big and small. Invest once, recycle forever, and watch discarded foam rise again as profit-friendly blocks. In short, the rebond foam machine doesn’t just recycle PU; it recycles your money right back into the business.

FAQs

How much space does the machine need?
About 40 m², including room for a chip bin and pallet exit.

Can it handle viscoelastic memory foam scraps?
Yes, but you’ll need to lower adhesive flow by 10 % for proper bonding.

What adhesive does the SA-9A use?
A water-based MDI blend supplied in 200 kg drums; alternatives are possible with vendor approval.

Does the press emit odors?
Steam carries most VOCs into a scrubber; the shop smells faintly sweet, not harsh.

How often should blades be sharpened?
Every 120 running hours, the HMI reminds the operator automatically.