Safa Foam factory is one of the pioneers of factories for industrial sponge, especially as it is the core of other products and the main raw material for many of them. Where the factory produces many products and meets the highest standards of quality and international standards and a consistent methodology and commensurate with the developments and needs of the market and industrial progress and the combination of quality and luxury. And because your comfort is our permanent goal, Safa Foam provides a guarantee on all products up to ten years.
Sponge is a porous material for rubber, rubber or other, similar to the absorption of the structure of the marine sponge animal. Sponge is used in many of the most important practical applications on sponge:
1- Manufacture of furniture: sponge took place of wool and wool in the furniture industry. Mattresses, bases, pedals and medical products.
2- Insulation: Sponges are used in heat and sound insulation operations, and used in the lining of food storage boxes, fillings of walls of buildings and others.
3 – Packaging: Sponge is used in packaging materials as protective equipment for different devices, because of its ability to absorb shocks and light weight and easy to form.
4 – buoyancy: manufacturers benefited from the feature of buoyancy in the sponge for the manufacture of buoys, boats and aircraft and life jackets.
5. Cleaning: The bathing fiber and the sponge of the domestic ports are produced from sponge, because of the ability of this material to absorb water and the overlap and transfer of cleaning materials.
6 – decorative paintings and lining.
Since its inception, Safa Foam has been keen on developing its production lines according to the highest international standards. Its production lines are divided as follows
1 – Department of Youth: The Department of Youth is the basis in the production of sponge and therefore SafaFom monitoring the best possibilities and the latest technology, where the section is the process of production of sponge through continuous production by the sponge machine equipped with a computer and work automatically From the calculation of the quantities of materials to the mixing process, which is paid to the mixing chamber at 4000 roll / min. All densities are produced according to the demands of our valued customers with high competitive quality. SOFT + HARD The machine is also equipped with a drop-down system that adjusts the surface of the sponge block according to international standards.
2 – Cutting section: The cutting section is the most important section where the sponge blocks produced from the production department and the conversion to multiple products (such as Arab sessions, mattresses, medical furniture and furniture of different sizes) according to market requirements, and given the sensitivity of this section and the accuracy required in the completed works, Safa Foam has identified the latest capabilities and advanced machines for this purpose.
3 – Types of sponge cutting machines: – Horizontal cutting machines (circular scissors): The circular scissors work to cut the spongy blocks horizontally and also cut the spongy length and width and control the height through the electronic board dedicated to this shear.
vertical shearing machines (vertical scissors): The vertical scissors are divided into blocks that were received from the circular scissors and converted into blocks that are delivered to the ready-made section or blocks to the scissor or drawing scissors according to the nature of the work orders issued on this machine.
rinsing machines which works to rinse the blocks at a certain angle according to the requirements of work, such as support, broom, etc.
Drawing machines: Scissors Drawing works on drawing and shaping spongy blocks and converting them into different shapes. In particular.
4 – Ready Department: is the section through which the receipt of orders of sponge from the cutting section is the last stage in the production process as either the delivery of the product to the customer or the deportation of orders to the sewing department equipped with the latest machines for sewing meetings and mattresses, furniture and furniture and works by technicians With expertise in this field. The ready-made department is the department that distributes orders, monitors traffic and orders…
The raw sponge industry consists of mixing a number of basic materials, activated auxiliary materials and optional materials that can be dispensed with and disposed of in the following:
Polyol: An alcohol containing multiple hydroxyl groups. It comes in a liquid state and gives flexibility to polymers. It has several molecular weights. This makes its uses different. In other words, the sponge produced for each partial weight has its own specifications. It is basically divided into three types as in the table below. In order to suit the final product specification it needs.
- Toluene diisocyanato 20-80 (TDI): An organic substance, an aromatic substance with a white, highly toxic pungent odor, if inhaled, causes irritation in the respiratory system and the eye. When handling or storing it, preferably using oxygen masks in case of dealing with it.
Water: It is used in production in small quantities compared to the other basic materials. The purpose of its use is to produce carbon dioxide when water is interacted with ISO-Sunnite and to increase the pores produced during the liquefaction phase. The more water is installed the less the sponge density is produced. This is a reaction to the heat, so be careful about the production of sponge with a density of less than 15 kg / m 3, usually uses an additional material beside the water inert and non-interacting reduce the heat in the heart of the cubes produced, so as not to ignite automatically from high temperature. Auxiliaries and Activators – Dimethylamine: A flammable organic compound, a colorless gas, with a strong odor. – Silicon. – Insulated paper in plastic (Kraft). Stannous Octoate. Optional materials 1 – 2 Chloride: A catalyst for the production of carbon dioxide, a toxic hazardous substance that must be carefully stored, handled and used.
2 – Stabilizers: Stabilizers help to reduce the heart temperature of the cube and prevent the combustion of the cube. Different types of inhibitors vary depending on the type of polyol used. These inhibitors help to reduce the surface stress rate of liquids during mixing. And helps to mix materials homogeneously as not to mix materials well leads to defects in the final product.
3 – inhibitors of color: are additional materials that keep the color of sponge for longer and delay the phenomenon of yellowing over time.
4 – Dyes: The purpose of their use is to distinguish the product in terms of density nothing more.
5 – Anti – ignition: When using sponges in the furniture industry Governments and international legislation recommend that there be controls on the speed of ignition of the product are added materials called anti – ignition, and there are many types of these important in the resistance to the elements of ignition sponges, but all have disadvantages where they work To increase the density of the final product, and reduce its shelf life.
Note: The production must be carried out in a well ventilated area due to high heat and toxic gases, and workers in this place must wear safety goggles and public safety tools.