How Foam is Made In a Factory? PU Foam, HR foam & Memory Foam कैसे बनता है?
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- Опубліковано 19 тра 2023
- U. V Industries,
Padadhari - Neknam Main Road, Vi. Neknam, Ta. Tankara, Di. Morbi - 363641
Contact Details - 9016479750 & 9898909652
thoriyaprit@gmail.com
How Foam Made In a Factory? PU Foam, HR foam & Memory Foam कैसे बनता है?
#howfoammade #foam #pufoam #memoryfoam #foamfactory #howtomake
Polyurethane foam is used primarily for bedding and furniture stuffing.
Isocyanates and Polyols
We have two foundational chemicals involved in the foaming of PU. Isocyanates and Polyols contain multiple hydroxyl.
In the foaming, the two most common isocyanates are TDI (for flexible and semi-rigid foaming) and MDI (for rigid foaming).
TDI + polyol has made polyurethane polymer, which now can be expanded to make foam. To do that, we add water. Isocyanate is highly reactive, and produces two things with water: urea linkages/urethane, and carbon dioxide (CO2) gas.
Blowing the Foam
The CO2 is considered primary blowing agent. As a gas, it blows little air pockets into the PU to form the foam. Just like blowing soap bubbles though, there is a point when the liquid casing cannot withstand the pressure of the air inside and bursts.
To successfully make material foam, the polyurethane must gel into shape once air has been blown to it. It’s harder than it sounds, and it’s also why foam technicians can make or break your factory production. The art of foam-making revolves around this sensitive balance between expansion, or blowing, and gelling.
Once they’re formed inside the polyurethane, we’re going to call the air bubbles cells. If the foam expands and gels before any air bubbles burst, you get closed-cell foams, which are semi-rigid (not truly rigid like foam made of MDI) since the material doesn’t bend as easily. To go back to our ladder metaphor, closed-cell foams are like wood ladders, whereas open-cell foams are like rope ladders. If some or all cell walls are allowed to rupture before gellation, you get a much more flexible material that bends, twists, and even breaks easier.
what is polyurethane foam? Basically: TDI, polyol, water, polymer, open versus closed-cell.
Additives.
see PU foaming additives by function. One of the most important additives is the catalyst, which can affect the basic reactions in several ways. It can speed the expansion, speed the gelling, cool the reaction (so you have less of a fire hazard on your hands), etc. There are also curing agents, which include chain-extenders and cross-linking agents. Chain-extenders, like their name suggests, extend polymer chains, which increases material flexibility. Cross-linking agents promote and strengthen cross-linkages, increasing structural integrity for more rigid foams.
Think of surfactants like emulsifiers. Oil and water on their own do not mix, but once you add some dish soap, they can be emulsified into a uniform mixture. Surfactants work like the soap. A more uniform mixture means a smoother reaction, and you get more even cell sizes, steadier reaction speeds, and finer control between gellation and foam collapse.
(The reason they’re called surfactants is because they reduce the surface, or interface tensions between two compounds. As in, the oil doesn’t just sit neatly on top of the water surfactants blend that interfacing surface between them.)
PU Foaming Chemistry oil
Remember that CO2 gas from the reaction with water acts as a blowing agent? other blowing agents may also be used or added. The main inconvenience of water blowing is the high temperature of the reaction, making PU foaming a fire hazard. Physical blowing agents (additives that physically encourage the expansion of cells instead of that initial CO2, which is chemically blown) reduce that fire hazard.
A similar additives is fillers. They come as particles or fibers. Particulate fillers can reduce flammability and add weight to foam (good for cushioning foams). Fibrous fillers reinforce cell structure. All fillers function to 1) add physical properties like tensile or compressive strength to foam, and 2) save on costs by reducing the amount of liquid chemicals used per batch.
The main ingredients are.
Isocyanate: TDI
Polyol: polyol
Blowing Agents: water, methylene-chloride (MC)
Catalysts: amine, tin
Surfactant: silicone
Now we understand what each element does during the foaming process. TDI + polyol begins the creation of polyurethane. A mixing head first injects small amounts of air into the liquid mix to kickstart the foaming process. TDI + water chemically produces the CO2 gas that blows the liquid into foam. In addition, we add MC so that less water is used in the initial reaction and the overall reaction temperature is lower, all while cell expansion is retained.
Meanwhile, the amine additive is doing multi-purpose catalysis (speeding the reaction) and tin provides a stable gelling catalyst, increasing foam structural elasticity. Silicone smooths and steadies the entire blowing process, maintaining cell structure evenness until gellation occurs.
This is reality of Indian manufacturer...no safety with Gloves...safety shoes ...gujju owner at there best
boss don't care if they don't have workers plenty waiting to take a job
We should appreciate the guys who has worked so hard to bring this knowledge and such a simple and explanatory way. these videos are for learning and not to finding issues in owners and employees. They have shown how simple is the foam making process wow!! Amazing !! the the chemicals used does not seems to create any safety or security issue than what is the point using cloves and glasses. will go out in park with safety glasses.
Catalyst increases the speed of reaction of different chemicals mixed.
बहुत बहुत अच्छी जानकारी दी है आपने थैंक्स ❤❤
Bahot hi badiya coverage on foam manufacturing process..... Kafi informative h.... Foam se naya business shuru kar sakte h😊
अच्छी जानकारी है। यूजफुल!
Such a valuable information sir..thank you
Nice to see youth of India making their presence in the market.
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Very good explain, the owner is very good man
Someone please tell them that methylene chloride causes cancer and the workers should at least use some gloves
such a great information sir...thank you
Bhut khub he vai
💐🙏💐
बधाई , जवान लोग बढ़िया काम , शुभ कामनाएं
💐🙏💐
Awesome 👌..million thanks
Amazing ..... bahut achhe bhai. It was really informative
Thank you🙏
Majama.....majama....🙏🏻🙏🏻
Nice to a younger person owner of the factory. Please do a video in English. Thanks
Thank you🙏
@@furnishingbro ja, please in englisch.
SUCH A GREAT INFORMATION SIR...THANK YOU..
Welcome🎉💐
Very simple and informative procedure but safety measures are gone for a toss. Will the concerned authorities impose some safety measures so that the workers can make a safe and and healthy living.
You are India’s Dr. Foam 🎉🎉🎉🎉
Right
Nice information about foam
great information sir....
जिसका आप इंटरव्ह्यू ले रहे हो उसे भी माईक देना चाहिए ता की ठिक से सूनाई दे
Yes, right
Budget nahi hoga yaar😂
Low budget Interview 😅
Yes hai 😂
😊
Very detailed, end to end video. Thanks!
Glad you enjoyed it!
Nice vlog, very nicely explained regarding every process to make pu foam.
Regards
Thank you🙏 for your valuable review💐
❤
Thank you
Good process overview, very informative. Thank you
Welcome🎉💐 Thank you for your valuable review💐🙏
It's full of wrong information 😂
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Your explanation is very good... thanks for making such videos
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Your explanation is excellent Bro
"Wow, this foam factory video is mesmerizing! 🤩 It's incredible to witness the process of transforming raw materials into a sea of fluffy, colorful foam. 🌈 The precision and efficiency of the machines are truly impressive, creating a captivating dance of foam particles. 💃🕺 I can't help but imagine all the creative possibilities that foam offers in various industries, from packaging to insulation and beyond. 📦❄ The video showcases the perfect blend of technology and craftsmanship, highlighting the dedication of the workers involved. 👏👷♂ Kudos to the team for sharing this captivating glimpse into the foam manufacturing world!
💐🙏
Phone number sent
Nice video
atleast raise question for labour safety..
Love this whole video!!
Good
nice video sir...good information regarding foam...
Achi jaankari di
🙏🙏
Superb and informative videos 👍
Thank you for your valuable review💐
Whole process of manufacturing foams are Very interesting. Thanks
Welcome and Thank you for your valuable review💐🙏
👍 👍👍👍👍👍 nice job
Good information.
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Good show
Hello sir How much capital will be required to set up foam manufacturing factory?
AROUND 4 MILLION DOLLARS
Very important video for me thankyou
Welcome🎉
Such a great video sir 🎉
Thank you🙏
❤❤❤❤❤ Amazing
Memory foam is the best😊
Good job
Very good video for education purpose. What foam actually made in this video? PU foam, HR foam or memory foam? Any chance you can show us how HR foam process being made? Thank you inadvance.
Will show sir👍🙏💐
Yes hai 😂🤣
Nice one
Thanks for information sir 🎉
Welcome🎉💐
Very knowledgable
Thank you🙏
Very. Nice. Exilant. Thanks
Welcome 🙏💐
Good morning, sir. Please activate automatic translation into all languages. I am from Jordan, one of your followers, and we understand what you are saying. May God bless you
Bravo
Very very good quality work
Thank you🙏
indians have no clear language, thank god our urdu is a such a clean concise language .
Katue mulle😂
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Very informative information you have viewed in video.
Thank you for your valuable review🙏
Здравствуйте какой компонент сирья используется для пена матрасы
a whole new meaning to "get it done at the lowest cost".
❤super
❤ good
Your videos have consistently captivated my intellect, for they possess an astounding ability to transcend mere information dissemination. They imbue one's consciousness with a profound impression, compelling an earnest desire to embark upon an entrepreneurial journey after immersing oneself in the compelling narratives you masterfully weave. I extend my deepest gratitude for the tireless endeavors you invest in delivering such exceptional content to us.
Each time I behold your presence, reminiscences of the visionary Steve Jobs spring forth, for akin to him, you are poised to introduce groundbreaking innovations into the uncharted realm of the mattress industry, propelling it into the realm of the "Sagar Bhai revolution"!
Kudos on your remarkable achievements! May you continue to grace us with such invaluable wisdom and enlightenment!
Really thank you sir🙏🙏 Thank you for your blessings🙏
are you the man's mother...you forgot to mention how the sun shines out of his rectal orifice.
@@DB12347 what, damn the master of sarcasm fooled by sarcasm, how embarrassing
😂
👌👌👌👌👌
Using the live stream feature on 4ra makes me feel like I'm at the game 📺👀
AAC block banana k liye kya use hota hai?
Chemical konsa konsa use hota hai?
The building's safety cannot be assured. No safety boots, gloves, or masks are worn. There are no warning signs for safety, such as No Smoking. There are no obvious chemical warning indicators. Poor storage of chemicals. Chemicals must be kept in a well-ventilated chemical storage area. No designated power control room makes the power supply extremely risky. Numerous unorganised, unsecured items in the area could hurt the workers.
👌
🙏💐
nice that you tell how its made, one problem, nobody is wearing any protection against gasses and chemicals. Be a better boss and take care of the protection off your workers and yourself !!
I dont think you understand what i am saying ? you are doing it very bad for your workers. take better care off them !!
how much will it cost to purchase this foam making machine
Thanks 🙏
Welcome🎉
Nice content, Hopefully you can make english subtitles to your video. Thanks
Mhje 5 bysada6 3 by sada6 hr bounding fom jo dikha rahe ho vo me chahiye kya cost hogi?
Wow good great video 👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻👍🏻
💐🙏
Hi viyrvre good news my favorite news ❤🎉
Excellent
Thank you for your valuable review🙏💐
Vacuum compressed karke delivery ya transport kartey to productivity aur bad jati
HR foam mattress ke liye good hoga aur kitne ka milega mujhe apne double bed ke liye hard wala foam chahiye
Bro,Would you kindly visit the bamboo ply factory as you are doing now and show how it's made🙏
👍👍👍
We need only POL+ISO, and also Heat at its all edges of cover. No other chemical required for PU foam. Yes, you can apply Acmose at the edges as releasing agent.
What are the materials bro??
@@sifeddinezeroual4860 as discussed above we only need Polyol and Isocynate at specific ratio. While pouring mould temperature should be on 45-55 degree.
What is POL ?
@@imrankhanafi5423 Polyol and Isocynide
Nice 👍
Thank you for your valuable review💐
Os produtos são forte o cheiro da reação química, se deixar os blocos juntos e perigoso pegar fogo devido a caloria da reação química, tem que deixar os blocos descansar sem encostar um ao outro, há caso que galpão pegou fogo
Translate to English because this is viewed in different countries where English is common. Thanks
Ok 💐Thank you
workers only wearing slippers 😅😅😅. At least wears shoes. Safety shoes.
Very informative video, Great
Glad you liked it
@@furnishingbrohow can i get contact with the factory
Good information 👍
Thank you🙏
Kya aap silicone sponge banate ho ?
Please reply
Good 👌
Thank you🙏
14 dec 2023 6:5 am est ( utc - 5 ) : thanks , just-now i finish seeing-with-fast-forward-rewind-repeatedly this movie . 8:12 pouring-process , 10:40 bucket-barrier-wall-removal , appear interesting .
Hi good information just question why no gloves and safety boots use
Yes sir.. We informed...
Super⭐🎉
🙏💐 thank you
Gidc आपका स्वागत
No सिफ्टी& लेबर ya गुजरात model है
Bhai you should have maintained the temperature of chemicals because it will decrease the pin holes.
Bhai pinhole ka problem mera vi hai
Sir, which is best Foam promo cool or hr in sleepwell? 🤔 🤔 🤔
HR
Foam banane ko konse matetisl lgte h....chemicdl k naam chahiye