Application: Rebonded Foam

Ecobelt 9: rebonding/recycling plant for flexible polyurethane foam

Rebounded foam plant for the recycling of flexible polyurethane foam waste from the production of flexible foam blocks in continuous. The customer is the largest polyurethane foam blocks manufacturer in his country and he would like to recycle his own scraps. He would like so to recycle his own scraps, turning his cost for disposing the waste coming from his continuous line into a profit by offering his customers the rebounded foam as well, completing his range of products offered on the market! This plant is mainly producing blocks of rebounded foam with density between 70kg/m3 and 120kg/m3 and can make both squared blocks (to then cut into sheets) or round blocks (for their peeling and then sold in rolls).

Ecobelt 8: rebonding/recycling plant for rigid polyurethane foam

Rebounded foam plant for the recycling of rigid polyurethane foam scraps coming from the waste of the production of continuous sandwich panels. The customer has a waste between 3% and 5% from his line, but taking into consideration of its massive production, he is getting a lot of foam to dispose as waste. Our customer is disposing every years 2.500m3 of polyurethane foam, meaning a cost of 30.000euro every year….and this cost is growing. On the other side, he is paying 50.000euro for the polystyrene spacers used for the stacking of his panels. The aim of the customer was to recycle his own waste for the production of spacers for the stacking of his own sandwich panels: in less than 2 years he repaid his capital investment. Furthermore he can highlight his production as green, with an unbelievable marketing advantage!

Ecobelt 7: rebonding/recycling plant for flexible polyurethane foam

Semi-continuous production plant of rebounded foam sheets from scraps of flexible polyurethane foam. The aim of the customer was to produce, in massive way, a ready-to-sell rebounded foam panels for sound insulation. That is why he selected our semi-continuous rebounded sheets plant, allowing a high rate production combined with reduced capital investment.

Ecobelt 6: rebonding/recycling plant for flexible polyurethane foam

Rebounded foam plant for the recycling of flexible polyurethane foam waste from mattresses’ production. The customer needed a massive production of rebounded foam sheets with the cover of non-woven to use in his production. That’s why he selected our rebounded foam plant in continuous, capable also to produce rebounded foam sheets with two layers as external surface of the sheet.

Ecobelt 5: rebonding/recycling plant for flexible polyurethane foam

Rebounded foam plant for the recycling of flexible polyurethane foam waste from mattresses’ production. The aim of the customer was to reuse its own scraps of flexible polyurethane foam coming from the trimming of blocks through its conglomeration. This plant is mainly producing blocks of rebounded foam with density between 70kg/m3 and 120kg/m3 to then cut into sheets to reuse in the mattresses as filling material for high load support.

Ecobelt 4: rebonding/recycling plant for rigid polyurethane foam

Rebounded foam plant for the recycling of rigid polyurethane foam scraps coming from the waste of the production of pipe section cut from block by a CNC cutting unit. The aim of the customer was to reuse its own waste for the production of sandwich panel with rigid polyurethane rebounded foam.

Ecobelt 3: rebonding/recycling plant for rigid polyurethane foam

Rebounded foam plant for rigid polyurethane foam. This plant was bought for recycling the scraps of trimming and calibration of high density polyurethane panels. The aim of our customer was not to bear anymore the cost of disposing polyurethane scraps and, in the meantime, to get a 250kg/m3 of rebounded rigid polyurethane foam block to then use as a master for the production of mould in the shipyard.

Ecobelt 2: rebonding/recycling plant for flexible polyurethane foam

Rebounded foam plant is used to recycle the scraps of a mattresses’ maker and of the trimming of blocks that are sold to converters. The aim of the customer was to get a rebounded foam as lightest as possible, so to use thin sheet in the mattresses as filling of top cover. Our plant was able to produce a 25kg/m3 density blocks with excellent bonding properties.

Ecobelt 1: rebonding/recycling plant for flexible polyurethane foam

Rebonded foam plant using our patented technology Ecobelt for the cost-effective production of rebonded foam, turning the cost of disposing polyurethane scraps into conglomerated items to sell on the market. The plant is recycling scraps coming from the production of mattresses, including the waste from the trimming of mattresses’ cover. This means that the plant is able to conglomerate different kind of material like polyurethane foam, fabrics scraps and cotton/wool filling material as in this application.