Carousel Foam Pillow Production Line

Small footprint
high degree of automation
strong expansion function
different modules can be selected according to different process requirements of users to achieve efficient production.

Compact structure

Small footprint, flexible layout, suitable for a variety of factory spaces.

Efficient operation

Automatic rotary workbench to achieve continuous production.

Manpower & labor saving

Automatic injection and demoulding to reduce manual operations.

Carousel Foam Pillow Production Line

The carousel pillow production line has a compact structure and a high degree of automation, and is suitable for medium-capacity production needs. The entire line is mainly composed of a foaming machine, a raw material storage system, a mold platform, a temperature control system, and a demoulding device. It supports multi-station continuous pouring and is suitable for a variety of pillow-shaped molds. It has the advantages of saving space, high efficiency, and scalability. It is an ideal solution for creating large-scale, standardized PU pillow production.

Specification Of Carousel Foam Pillow Production Line

Turntable cable diameter	Customizable
Number of Workstations	Within 80 stations
Height of the turntable line from the ground	400 mm
support wheel	20
running speed	Adjustable from 4 to 12 minutes per revolution
driving mode	Reduction unit
Reducer power	5.5 kilowatts
Load capacity of the center support	3 0 t
Disk loading	3 0 t
Thickness of rotating line steel plate	6mm
Wire skeleton of a turntable	10 mm I-beam (national standard)
steel track plate	16 mm steel plate

Components Of Carousel Foam Pillow Production Line

Mold Bases

Of Carousel Foam Pillow Production Line

The pneumatic formwork system consists primarily of the lower mold base, support plate, upper mold base, mold opening cylinder, clamping pin, clamping cylinder, clamping air bag, guide rod, safety pin cylinder, compression spring, pneumatic control valve, connecting shaft, and other components, as well as an electrical control box. The main body of the formwork system is machined and formed by section steel welding, making it both firm and beautiful.

Loading template size	left and right 800 mm Front and rear 900 mm
Closed mold height	to be determined
Clamping force	up to 4000kgf
Airbag stroke	30 mm
Air source pressure	cylinder air source 0.6-0.8Mpa
Air bag air source	0.2- 0.3Mpa
Solenoid valve control voltage	DC24V

Polyurethane Pillow Molds

Of Carousel Foam Pillow Production Line

High-precision processing：The mold is made of aluminum alloy or steel, with precision processing and stable structure.
Excellent thermal conductivity：Fast heat conduction helps constant temperature control and rapid curing of the mold.
Fine surface treatment：Smooth surface and clear texture ensure uniform texture of the finished pillow.
Support multi-cavity design：Single-cavity or multi-cavity molds can be customized to improve production efficiency.
Adapt to a variety of materials：Suitable for PU systems such as slow rebound, memory foam, cold curing, etc.
Compatible with a variety of production lines：Widely used in automated production lines such as disc lines and banana lines.

Robot Arm

Of Carousel Foam Pillow Production Line

Precise pouring: The robot arm automatically controls the movement and positioning of the foaming head to ensure accurate and uniform injection of raw materials.
Efficient operation: It can continuously and quickly pour multiple stations, greatly improving production efficiency.
Synchronous control: It is linked with the foaming machine and the disc platform to unify the operation rhythm and ensure smooth rhythm.
Reduce labor: Replace manual pouring, reduce labor intensity, and reduce human errors.

Robot model	GP180	GP12
Degree of freedom	6	6
Horizontal extension	2702mm	1440mm
Transportable mass	180kg	12kg
Main body mass	1020kg	130kg
Repeat positioning accuracy	±0.05mm	±0.02mm
Controller	YRC1000	YRC1000,YRC1000micro
Protection level	Main body: IP54, wrist axis: IP67	Main body: IP54, wrist axis: IP67
Installation method	Floor mounted	Floor-mounted, wall-mounted, inverted, tilted
Purpose	Transportation, picking/packaging, palletizing, assembly/disassembly	Transportation, picking/packaging, palletizing, assembly/disassembly

Mold Temperature Controller

Of Carousel Foam Pillow Production Line

Precise temperature control and sensitive response: PID control algorithm is used to automatically heat or cool the medium to achieve precise adjustment of mold temperature.
Wide voltage input: supports AC85~265V wide range input, suitable for most power grid environments in the world.
Multiple temperature protection functions: built-in high temperature alarm, low temperature alarm, heater overheat protection, excessive temperature difference alarm, etc.
Multi-signal acquisition: supports K-type thermocouple input, and can simultaneously monitor water inlet temperature, water outlet temperature, and pump current.
Fault self-check and alarm: It has 11 error code alarms (such as lack of liquid, reverse phase, sensor failure, etc.), and has sound and light alarm and display functions.
Intelligent operation status display: The front panel LED indicates the current operation status, including heating, cooling, operation, fault and other modes.
Humanized operation interface: supports multiple user functions such as timed power on and off, temperature unit switching, operation timing, parameter locking and recovery.

Vacuum Bubble Crusher

Of Carousel Foam Pillow Production Line

Dual vacuum and mechanical foam breaking systems, suitable for framed and frameless foam
Multiple vacuum stages + multiple rolling groups, effectively breaking bubbles while avoiding material rupture
High-precision position sensing and vacuum value display, the entire process is visible and controllable
All chains are equipped with protective covers, and all systems use 24V safe voltage
HMI can display key information such as vacuum value, belt speed, and running time
Foam thickness: 100-200mm
Length: 300-1200mm
Width: 200-800mm

Punch Machine

Of Carousel Foam Pillow Production Line

Punching method: pneumatic/hydraulic punching, optional customized electric servo control
Number of punching holes: supports 4~30 holes (settable)
Punching speed: 8~12 pieces/minute (depending on the number of holes and density)
Aperture range: φ3–10mm adjustable
Punching depth: 0–60mm adjustable, precise positioning
Applicable pillow size: length 400–700mm, width 300–400mm
Stable frame structure, small footprint
PLC control, stable operation
The punch is made of high-strength alloy steel, wear-resistant and heat-resistant
Complete safety shield, equipped with emergency stop button

Polyurethane Raw Materials

Of Carousel Foam Pillow Production Line

Slow rebound, fits the neck curve, and improves comfort;
Adjustable density (commonly 40-60 kg/m³), taking into account both support and softness;
After the raw materials are mixed, the reaction is stable and the foaming is uniform, which is suitable for mold casting production;
Environmentally friendly and odorless formulas can be selected, which meets the environmental protection requirements of the European and American markets for VOC release.

High Pressure PU Foam Machine

Of Carousel Foam Pillow Production Line

High mixing efficiency：Using high-speed impact mixing head, the raw materials are mixed more fully and evenly, ensuring stable foaming quality.
Accurate metering：Equipped with a high-precision metering pump, the mixing ratio error is ≤±0.5%, meeting the needs of refined formulas.
Automatic control：Equipped with PLC touch system, parameter visualization management, support automatic cleaning, fault alarm and other functions.

Customer Cases Of Carousel Foam Pillow Production Line

A home furnishing company located in the central United States, focusing on the manufacture of high-end slow-rebound memory pillows. When expanding its production capacity, the customer chose the automated disc-type pillow production line provided by our company. The entire line configuration includes a high-precision foaming machine, a multi-station disc platform, a mold temperature control system and an automatic demoulding device, achieving a daily output of more than 3,000 pillows, and an increase in production efficiency of more than 40%.
After installation and commissioning, the customer highly recognized the stability of the equipment and the consistency of the finished product, and plans to introduce a second production line in the next stage to further expand production capacity. This project also successfully helped the customer to expand the brand influence of customized memory pillows in the North American market.

After the equipment was delivered, the customer quickly completed the installation and commissioning. At present, it has achieved a stable output of more than 1,000 pieces of seat foam per day. It highly praised the efficiency and operating experience of the equipment, and continued to negotiate with us for cooperation on the second production line.

Carousel Foam Pillow Production Line

Compact structure

Efficient operation

Manpower & labor saving

Carousel Foam Pillow Production Line

Specification Of Carousel Foam Pillow Production Line

Components Of Carousel Foam Pillow Production Line

Mold Bases

Of Carousel Foam Pillow Production Line

Polyurethane Pillow Molds

Of Carousel Foam Pillow Production Line

Robot Arm

Of Carousel Foam Pillow Production Line

Mold Temperature Controller

Of Carousel Foam Pillow Production Line

Vacuum Bubble Crusher

Of Carousel Foam Pillow Production Line

Punch Machine

Of Carousel Foam Pillow Production Line

Polyurethane Raw Materials

Of Carousel Foam Pillow Production Line

High Pressure PU Foam Machine

Of Carousel Foam Pillow Production Line

Customer Cases Of Carousel Foam Pillow Production Line

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