Foam Recycling Machine

GENMAX manufactures PU foam recycling machines for mattress, furniture and automotive plants that generate polyurethane offcuts. The range covers the full scrap-to-block process: pre-shredding of bulk waste, crushing into controlled granule sizes, and steam-assisted rebonding into dense blocks ready for cutting and resale. All machines are built in our own factory and shipped factory-direct, with installation guidance, operator training and after-sales support included.

Note on scope: these are machines for flexible polyurethane foam — mattress offcuts, furniture trim waste, carpet underlay scrap and automotive foam. They are not EPS or styrofoam densifiers, which handle a different material and process entirely.

Why Foam Plants Invest in Recycling Equipment

Foam offcuts are a cost twice over: you pay for the material once, then pay again to have it hauled away. A trim loss of 5–10% is normal in mattress and furniture cutting, and for a plant of any size that adds up to tonnes per month going out the gate as expense.

Rebonding turns that stream into a product. Crushed foam chips are bonded under steam and pressure into blocks at 50–150 kg/m³ — the density range used for carpet underlay, sports and gym flooring, packaging inserts, seat cushions and mattress base layers. Plants either sell the blocks outright or cut them and feed them back into their own product line.

The economics are straightforward: input material costs nothing because it is already your waste, and the recurring spend is adhesive (MDI prepolymer and catalyst) plus boiler fuel and one operator.

Our Foam Recycling Machine Range

Foam Rebonding Machine (RF02 series)

The core of the line. A 10 m³ mixing tank blends crushed foam with adhesive, then discharges directly into the mold where steam is introduced from the bottom for even curing. Output runs from 10–15 blocks per 8-hour shift on the single-mold RF02 up to 35–45 blocks on the dual-mold configuration with top weighing bin. Density is adjustable across 50–150 kg/m³ through press pressure and adhesive ratio. Rectangular and cylindrical molds available; cylindrical is the choice for plants that will peel the block into sheet.

Foam Shredding Machine / Crusher (PS3878)

Processes 900 kg/hr with a single operator, producing granules from 0.5 to 50 mm. High-density foam can be taken below 2 mm for hi-poly shoe pad applications. Handles foam leather scrap, waste cloth, PU elastomers and soft plastics as well as standard mattress and furniture offcuts.

Foam Scrap Pre-shredding Machine (PS-8000)

Breaks down bulk waste — whole rejected mattresses, large block offcuts, baled scrap — into pieces the main crusher can accept. Plants processing their own cutting waste in small pieces can often skip this stage; plants buying in scrap or handling end-of-life mattresses cannot.

Not sure which combination fits your scrap volume? Tell us the tonnes per month you generate, the foam types involved, and whether you plan to sell blocks or consume them in-house — our engineers will size the line and send a layout.

Frequently Asked Questions

What types of foam waste can be recycled?

All flexible polyurethane foam: mattress offcuts, furniture and sofa trim waste, carpet padding scrap, automotive foam components, foam leather scrap and PU elastomers. Different densities can be mixed in the same batch. Rigid PU, EPS and styrofoam require different equipment and are outside this range.

What density of rebonded block can the line produce?

50 to 150 kg/m³, adjusted through press pressure and adhesive ratio rather than any mechanical changeover. Lower densities suit packaging and filling; the 100–150 kg/m³ range is used for sports flooring, industrial subfloor and heavy-duty seating.

How long is one production cycle?

15–25 minutes per block depending on size and target density. With a dual-mold system the effective cycle drops to 8–12 minutes because one mold cures while the other is being filled.

What adhesive and consumables are required?

MDI prepolymer with an amine catalyst — the standard for foam rebonding. We provide supplier recommendations and the technical specification for your target density. Boiler fuel is the other recurring cost; the standard 200 L boiler runs on diesel, with electric and gas options available for indoor installations or sites with diesel restrictions.

How much floor space and what utilities does the line need?

Space depends on configuration; we produce a layout drawing against your floor plan before production starts. Machines run on three-phase power and can be configured to your local voltage. A steam boiler installation may require local pressure vessel approval — we supply the documentation your inspector will ask for.

Do you provide installation and operator training?

Yes. Forty hours of operator training covering operation, maintenance, troubleshooting and safety is included, along with installation guidance. Lead time is typically 30–90 days depending on configuration.

Can the machines be customised?

Yes. Mold tank size, boiler capacity and mold shape are all configurable, and our engineering team returns a customised proposal within 72 hours of receiving detailed requirements.

See how an Uzbekistan factory turned its foam waste into a revenue stream with a GENMAX recycling line.