Auto Roll Foam Line Design and Optimization

With the impact of globalization, the competition dimensions among enterprises began to differentiate. Businesses should investigate to provide new production methods to adapt new competitive conditions. In order for the enterprises to respond quickly and in the desired quality to the consumer demands; production system depends a new understanding which is kept waiting at a low level and most importantly all wastes are eliminated and without staff. The project has been developed for the production of roll foam. Foam sector is growing fast and 8 million in domestic market in 2017 sales volume reached. 45 percent of the market is composed of roll foam. The annual growth rate of the sector is 5 percent; the market size is close to 1 billion TL. The subject of the project is about the production of sofa, bed, automotive, home textile, medical products, lamination etc. Foam is the main input of the production activities.Today, almost all of the foam production stages in our country are realized with the labor force. Foams coming from the casting and waiting on the shelf are taken to the conveyor by shuttle and transported to the foam peeling machines by crane for cutting. In the scope of the researches, roll foam production machines that work in different logic are examined. There is no roll of foam production machinery manufacturers in Turkey. In this sector, there is no integrated structure or similar work that will produce cylinders that automatically take the foam from the shelf. The project will be the first industrial 4.0 application in the sector.With the machine and special software developed in our company, customer demand will be answered quickly. The aim of the project is to design and implement a system that will produce a roller foam having a diameter of 1.6 m or more and a thickness of 5 mm or less from a 30 mm block foam. One of the main performance indicators of our project is to increase our foam cutting speed to 70m / min. For this purpose, cutting speed parameters have been formed according to foam density by using plc controlled servo motors.The project will produce mixed structure foam and will provide an infrastructure for export. With the new line to be designed in CAD environment, one operator will be used instead of 5 operators, 30 m block foam will be poured instead of 15meter block foam. The foam roll will be cut for less than 5 mm thickness for the first time in the foam cutting plant and rolled into rolls larger than 1.6 meters.