IF-FF3 Box Foaming Machine: Produce Custom Density Foam Blocks In-House

PLC-controlled box foaming machine. Produce custom-density foam blocks (8-80 kg/m³) in-house. 3-component mixing, touch screen control for up to 10 recipes.

Jun 30th,2026 6 Views

BOX FOAMING

IF-FF3 Automatic Box Foaming Machine
Produce Custom-Density Foam Blocks In-House with PLC Control

Stop buying foam blocks from suppliers. Produce your own with the IF-FF3 at densities from 8 to 80 kg/m³.

If you buy foam blocks from a supplier, you know the pain: long lead times, minimum order quantities, limited density options, and quality that varies from batch to batch. The IF-FF3 Automatic Box Foaming Machine puts foam production in your hands. You buy raw chemicals once and produce foam blocks on demand at exactly the density, size, and formulation you need.

A furniture factory in Mexico was spending $4,200 per month on foam blocks from their supplier and waiting 10-14 days per order. They purchased an IF-FF3 and began producing their own blocks. Their monthly foam cost dropped to $2,100, and they eliminated delivery delays entirely. The machine paid for itself in 8 months.

Why the IF-FF3 Box Foaming Machine?

The IF-FF3 is a compact, automated box foaming line designed for medium-scale foam production. It combines raw material storage, mixing, dispensing, and foaming in one integrated system. The machine uses a PLC + touch screen control to manage the entire foaming process.

Here is how it works: raw polyol and isocyanate are stored in day tanks. The operator selects a formula on the touch screen. The machine meters both components at the programmed ratio, mixes them in a high-torque mixing head, and dispenses the mixture into a box mold. The foam rises in 3-5 minutes and is ready for demolding after 15-30 minutes of curing time.

IF-FF3 Automatic Box Foaming Machine

PLC-controlled box foaming machine. 3-component mixing. Produces foam blocks 1550-2050mm wide, density 8-80 kg/m³. Touch screen control.

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Technical Specifications

Specification	IF-FF3
Foaming Groups	3 groups
Foaming Width	1550-2050 mm
Foaming Length	2050-3050 mm
Foaming Height	Up to 1250 mm
Density Range	8-80 kg/m³
Output Rate	260 L/min
Mixing Head Power	11 kW
Machine Size	L10000 × W7000 × H3500 mm
Control System	PLC + Touch Screen

Key Features

PLC touch screen control: Store up to 10 different foam formulations. Switch instantly between recipes. The system monitors temperature, mix ratio, and pour rate in real time.
3-component mixing: The machine supports polyol, isocyanate, plus one additive stream. This allows you to produce specialty foams including memory foam, high-resilience foam, and filled foams.
Adjustable mold size: The box mold adjusts from 1550mm to 2050mm width and 2050mm to 3050mm length. One machine covers multiple product sizes.
Automatic dispensing: Once the formula is set, the machine handles the entire pour cycle automatically. The mixing head moves across the mold for even distribution.
Variety of foam types: The IF-FF3 produces soft polyurethane foam, memory foam, high-resilience foam, filled foam, and more. Density range covers furniture, mattress, packaging, and automotive applications.

Applications

Mattress foam cores: Produce mattress-grade foam blocks in densities 15-50 kg/m³ for cutting into mattress layers. The mold size directly accommodates twin, full, and queen mattress dimensions.
Furniture cushion blocks: High-resilience foam for sofas and chairs at 25-50 kg/m³. The adjustable mold lets you produce blocks optimized for your cutting patterns.
Packaging foam: Low-density foam blocks (8-15 kg/m³) for protective packaging. Produce on-demand instead of stocking foam from suppliers.
Automotive foam: Medium-high density foam at 40-80 kg/m³ for vehicle seating and interior components.

ROI Analysis: Buy vs. Produce Your Own Foam

Cost Factor	Buying from Supplier	Producing with IF-FF3
Foam cost per m³ (density 25 kg/m³)	$80-120	$35-50
Lead time per order	7-14 days	Same day
Monthly cost (200 m³)	$16,000-24,000	$7,000-10,000
Density control	Limited to supplier range	8-80 kg/m³, any blend

With an investment of approximately $15,000-25,000 for the IF-FF3, monthly savings of $8,000-14,000 mean the machine reaches payback in 2 to 3 months for medium-volume producers.

Related Foam Production Equipment

Complete your foam production line with these complementary machines:

IF-FF4 Continuous Foaming Plant — for high-volume continuous block production. When your output exceeds the IF-FF3 capacity, the IF-FF4 handles continuous foaming at higher speeds.
IF-FPQ1 Horizontal Foam Cutter — slice the blocks produced by the IF-FF3 into precise sheets. Pairs perfectly for a complete in-house foam production line.
IF-FZS1/2 Re-Bonding Machine — recycle foam scrap from cutting operations into rebonded blocks for packaging and industrial use.