Application Report 11
The Problem...
Reprocessing Polyurethane FoamFuture Foam, Inc. of Council Bluffs, Iowa, a leading manufacturer, fabricator and reprocessor of flexible polyurethane foam, produces large foam "Buns" which are cut into various custom pieces for furniture, toys, etc. The cutting process leaves random size pieces called off-fall which is reprocessed and rebonded into suitable sections for other products such as bus and boat seats, carpet underlay, etc. The off-fall pieces were baled and shipped to their rebonding plants in Denver, CO., and Madison, WI. Feeding of large, bulky, irregular pieces of off-fall into an inadequate baler resulted in loosely packed and irregular bales -- only 40,000 pounds of baled material could be loaded into a railroad car. Not only was the baling system slow, allowing only 1/4 ton per shift to be baled, but it was accumulating at a faster rate than could be baked, thus taking up valuable production floor space. Large, irregular pieces also tend to clog the hammermills at the rebonding plants, reducing their efficiency and output, as well as causing excess maintenance.
The Solution...
A top feed "Piggyback" ShredderFuture Foam installed the BloApCo Model 3JK42-2536BV top feed "Piggyback" Shredder over a new reconfigured standard AMBACO 10,447 Series extrusion type baler with auto-tie. BloApCo's unique "Pierce-and-Tear" shredder action reduced the foam to smaller sizes that could be readily baled, thus producing more uniform bales that were almost twice as dense as the unshredded bales. The shredder's "Pierce-and-Tear" action actually pulls the foam into the shredder. For safety purposes, an infeed conveyor that incorporates the safety overweight plate, carries the foam into the shredder. Results have been excellent at Future Foam. Hauling costs have been cut in half. Now 70,000 lbs. can be loaded into a rail car and five tons per shift are baled. The scrap pile has been eliminated and the hammermills have increased their output by 25% with far less wear and tear on the machines. The system operates almost automatically with full automatic operation planned in the near future.
Application Report 11
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