What is the product?
The Foam Blender, as it is known within Memory Foam Warehouse, part of the GNG Group. Bought from Chinese manufacturing company Shenzhen Xinqunli Machinery, the machine is capable of processing up to 120kg of foam per hour, turning clean offcuts of foam into penny-sized cuboid pieces. These are then used to make high-quality pillows and dog beds. This machine enables us to maximise our stock production without the need to purchase more foam blocks, reducing waste.
How does it work?
The machine has two sets of interlocking rollers. As the foam sheet is fed through, the first set of rollers cuts the sheet into ribbons. The second set of rollers, rolling the opposite way to the first set, then cuts the ribbons into cubes.
Where would it ideally be used?
At foam converters, such as Memory Foam Warehouse, that buy big blocks of foam and convert them into mattresses and pillows. This machine enables us to make more products from each block of foam we purchase, reducing waste. On a product level, the Foam Blender creates small, uniform-sized cubes from our high-quality offcuts, so it is perfect for making superior cluster pillows and dog beds.
How is it different?
The Foam Blender offers a cost-effective solution to excess waste. There is a company based in Germany that converts waste foam into its constituent chemicals, but this is unlikely to become commercially viable due to high costs.
What benefits does it offer?
Memory Foam Warehouse is always keen to look at ways to reduce product wastage and manage its manufacturing carbon footprint. These are the main ‘green’ benefits of the machine, as we do not have to transport our waste to various companies across the UK to reprocess it, or put it into landfill.
Where has it been used?
The Foam Blender is in our Leeds warehouse where foam-based mattresses and healthcare products are cut. We have skilled operators to manage the machine at all stages, from feeding in the foam offcuts through to processing the finished product. Our own design engineers have produced the product specifications for the end recycled products.
The machine costs approximately £50,000.
The machine saves us money as we are able to use our foam offcuts to make new products, rather than spending money to transport excess pieces to be reprocessed or disposed of. The fact that the Foam Blender allows us to make cluster pillows filled with high-quality, uniform-sized cubes using clean offcuts of foam means that we can offer customers a superior product for the same price.
What about maintenance?
The machine is virtually maintenance-free, it just requires regular cleaning.
What is its life span?
The machine’s lifespan is about 20 years or more.
How is it future-proofed?
Foam technology is unlikely to change and there will always be a need to recover waste. In this way, the Foam Blender is future-proofed, and a great investment for our company.
As a leading memory foam mattress supplier, we predominantly use reflex foam, memory foam, natural Talalay latex and nursery foam to produce thousands of mattresses for adults, children and pets each year. With such a high level of product output, taking these steps to recycle waste into high-quality products will make a big difference to our impact on the planet.