From Foam Waste to Value: Uzbekistan Factory’s Recycling Success with GENMAX

Is foam waste piling up in your factory? Disposing of it only increases costs and hurts your bottom line. What if you could transform scrap foam into valuable products? You’d reduce waste and save money at the same time.

A mattress factory in Uzbekistan faced this exact challenge.

They needed a reliable and efficient way to process foam scraps and transform them into rebonded foam blocks for carpet underlay and gym mats.

GENMAX provided a custom solution featuring two key machines: the PS3878-PU Foam Crushing Machine and the RF02 Foam Rebonding Machine. This setup created a complete foam recycling line that transformed their operations.

Foam Waste Was Draining Resources

• Foam scraps and cloth waste cluttered production areas
• No efficient system to reuse or recycle foam leftovers
• High costs from constantly buying new raw foam materials
• Needed a recycling line that could handle different foam densities and scrap types

If your factory struggles with foam scrap piling up, this story might spark some ideas.

GENMAX Machines Built for Efficient Foam Recycling

PS3878-PU Foam Crushing Machine

• Shred foam scrap into uniform granules
• Large feeding port and crushing port
• Output capacity of up to 1,000 kg/hour
• Four rows of fixed knives and three rows of rotary knives ensure thorough crushing
• Powerful 35.5 kW motor designed for continuous industrial use
• Compact footprint fits factory floors without hassle

RF02 Foam Rebonding Machine with Steam

• Converts shredded foam scraps into strong rebonded foam blocks
• Produces both rectangular and cylindrical blocks for versatile applications
• Advanced mix system prevents crystallization during processing
• Built-in weight display meters glue and steam with accuracy for consistent bonding
• Hot press technology applies exact pressure and temperature for durable blocks
• Weight box measurement guarantees consistent material dosing each cycle

How the Recycling Line Works in Practice

1. Shredding: Foam scraps crushed into granules by the PS3878-PU machine
2. Mixing: Granules blended with glue and chemicals in a mixing vessel
3. Molding: Mixture poured into molds, pressed, and steamed in the RF02 machine
4. Finishing: Blocks cooled, edges trimmed, then cut into sheets or custom shapes

This system transforms foam waste into top-notch rebonded foam blocks. These blocks are used for carpet underlay, gym mats, packaging, and acoustic panels. This process cuts down on waste and opens new revenue opportunities.

What GENMAX Delivered

• Expert installation: Our engineering team handled installation, commissioning, and testing on-site, ensuring smooth operations from day one
• Customized solutions: Machines tailored to handle the client’s specific foam scrap types and densities
• Sustainability improvements: The factory reduced foam waste by 90%, significantly cutting raw material costs
• Industry experience: Over 15 years in mattress machinery and recycling technology with more than 5,000 successful projects worldwide
• Complete project management: We optimized every step from delivery through testing
• Local support: Nearby service centers and technical teams ready to assist when needed

Benefits for Your Factory

If foam scrap is accumulating and driving up costs, consider these strategies:

• Invest in crushing and rebonding equipment matched to your foam types and scrap volumes
• Use precise adhesive and steam control to produce consistent, durable rebonded foam blocks
• Partner with suppliers who provide comprehensive on-site support throughout installation and testing
• Monitor your recycling line closely to maximize output and minimize downtime
• Embrace sustainability — recycling foam reduces disposal fees and raw material purchases

Key Considerations for Foam Recycling Equipment

• Capacity: Can the crusher handle your scrap volume without creating bottlenecks?
• Output quality: Does the rebonding machine produce blocks that meet your product specifications?
• Process control: Are adhesive and steam systems accurate and adjustable?
• Installation support: Will engineers be on-site to ensure smooth startup and operator training?
• After-sales service: Is local technical support available for quick troubleshooting?

Performance Comparison: Traditional Foam Waste Handling vs. GENMAX Recycling Line

Sources

• United Nations Environment Programme, “Sustainable Foam Recycling Practices,” 2024 Report
• Uzbekistan Ministry of Industry and Trade, “Manufacturing Waste Reduction Initiative 2025”