Polyurethane foam is one of the most versatile plastics used today. To manufacture polyurethane foam you need the following basic equipment: material supply containers, metering units, mix heads, temperature control systems, and process control systems. Depending on the complexity of the line, other specialty equipment may be needed, but these basic components can get the job done.

Material supply containers are used in many phases of the manufacturing process. First, the raw materials are delivered in some kind of container like a tote bin or drum. Alternatively, if you receive your raw materials via tank car or railcar then you will need some kind of container to transfer the materials to. Materials can also be stored in blending containers or intermediate storage tanks.

Metering units are needed to deliver all raw materials to the machine in varying speeds and manners. Metering units are considered either low-pressure, high-pressure, or some combination of the two. Whatever type you use, materials need to be delivered to the mix head with plus or minus 1 percent accuracy. Sometimes materials are used at rates of ounces per second and other times in quantities as large as 1000 lb/min.

Mix heads are where all the action happens. Materials are mixed either mechanically in a low-pressure system or with impingement mixing in high-pressure systems. Low-pressure systems give excellent mixing but need to be purged quite often, which can slow down production. High-pressure systems do not need purging or flushing but you need to perfect the diameter in order to prevent poor mixing or splashing.

Finally, your process needs to be maintained by temperature and process control systems. The temperature control system will make sure your product is consistent by accounting for any heat generated by the mechanical aspects of production. The process control system can be as simple as an on and off switch or very complicated because they monitor, control and provide data for statistical analysis. These parts of the manufacturing line will account for the bulk of the cost of the entire system but are critical to producing quality material in a timely manner.