How Rebonded Foam Is Made: From Scrap to Block

Rebonded PU foam is a secondary foam material made from recycled PU foam scrap. Instead of discarding trim, offcuts, and used foam, we shred the scrap, mix it with a PU binder, and press or mold it into blocks. Those blocks are then cut to shape for replacement of virgin foam in furniture padding, farming mattress, domestic mattress, and modular autoparts. For purchasing managers and technical buyers, understanding the basic steps helps you ask better questions about grade, density, binder, block size, and cutting tolerance.

What Rebonded PU Foam Is

Rebonded PU foam is made with recycled PU foam and is 100% recyclable. It is designed as a replacement for virgin foam in furniture padding, farming mattress, domestic mattress, and modular autoparts. Available density ranges from 50kg/m3 to 300kg/m3, and shape cutting is supported. Because the input is scrap, the final block quality depends heavily on the scrap grade, the shredded chip, the binder, and the forming process. For buyers, the key variables to agree on are grade, density, binder type, block dimensions, and cutting tolerance. For a product overview, see rebonded PU foam.

Feedstock: Graded PU Foam Scrap

Rebond production starts with PU foam scrap. Not all scrap is the same. We commonly sort it into grades:

• Grade AA: around 5% skin or 0-skin versions; density 20-30kg/m3. This is a higher-grade stream.
• Grade A: 5% skin and 15% skin versions.
• Grade B: around 15% skin.

Color options include black, white, and mixed. Other feedstock streams include memory visco (memory foam) scrap, shredded foam, filter foam scrap, Dali skin foam, Hi-Poly shoe foam scrap (50-60 density), crushed fabric bra foam scrap, and old used foam. Each stream behaves differently in the rebond process. Skin content, foam type, color, and contamination affect how the chips bond and how the finished block cuts. Old used foam and mixed streams can vary more than factory trim, so grading and sorting matter. For more detail on grades, see PU foam scrap and the grade comparison at foam scrap grades explained.

From Scrap to Shredded Chip

Before bonding, scrap foam is reduced in size. Shredded foam gives the binder more surface area to coat and helps create a more uniform block. In practice, the shredding step may include sorting, removal of non-foam material, and screening. The exact chip size, screening method, and contamination limits depend on our process and the target product. Tell us if you need to specify chip size or incoming scrap condition. Shredded foam is also supplied as a standalone feedstock; see shredded foam.

The Role of PU Binder

PU binder is the adhesive that bonds foam chips together. During production, binder is applied to the shredded foam, and the coated chips are then formed into a block. Binder selection and application affect block strength, flexibility, and how cleanly the foam can be cut. Binder is a separate input, not part of the foam scrap itself. We don't publish fixed mix ratios or process settings — ask us for technical details. PU binder is supplied as a separate product; see PU binder.

Forming the Block

The coated foam chips are molded or pressed into blocks. The block density is influenced by the foam scrap density, the amount of binder, and the degree of compression during forming. Block dimensions should be agreed before production, especially if the blocks will be cut into sheets or profiles.

Cutting and Finishing

After forming, blocks are cut to shape. A block can be converted into sheets, pads, profiles, or other formats for furniture padding, farming mattress, domestic mattress, and modular autoparts. Cutting tolerance, surface finish, and edge quality are practical buying points. Ask us for cutting capabilities and tolerance details for your drawing or sample. If you are comparing rebonded foam with other materials, the density guide at rebond foam density guide can help frame the discussion.

Quality Checks Buyers Should Discuss

Because rebonded foam is made from scrap, buyers should agree on measurable quality points before ordering. Useful discussion items include:

• Scrap grade: AA, A, or B, and the skin percentage.
• Color: black, white, or mixed.
• Feedstock type: standard PU scrap, memory visco scrap, shredded foam, filter foam scrap, Dali skin foam, Hi-Poly shoe foam scrap, crushed fabric bra foam scrap, or old used foam.
• Finished density: within the 50kg/m3 to 300kg/m3 range.
• Block size and cutting: block dimensions, sheet thickness, profile, and tolerance.
• Binder: the PU binder specification and how it is applied.

Logistics and Order Basics

Alibaba-listed supply ability of 5000 Ton/Tons per Month. Ports are Shenzhen or Guangzhou, China. Scrap foam is commonly supplied at density 15-30kg/m3, with 200-300kg per bale. A 40ft container loads 18000-22000kg, and one 40HQ loads 20-22 tons of AA-grade compression bales. Container loading depends on bale compression and grade, so confirm bale weight and compression with us. Payment terms include T/T, L/C, D/P D/A, MoneyGram, Credit Card, Western Union, and Cash. Main markets are Mid East, South America, Southeast Asia, Africa, and Domestic Market. Fungbillion is a manufacturer and trading company in Guangdong, China, located at ChaoLang Industrial Zone, Chashan Town, Dongguan City, Guangdong, China.

What to Tell Us When You Inquire

To get a useful reply, tell us your target density, application, required grade (AA, A, or B), skin preference, color, and whether you need blocks or cut shapes. Include block size, sheet thickness, drawing or sample details, order quantity, preferred port, and payment terms. If you are comparing rebonded foam with other padding materials, tell us the application so we can discuss the right density and format. Contact Ms. Vicky Chen, Sales Manager, at [email protected], office tel 0086-0769-81805003, mobile 0086-15875576145, or WhatsApp 15875576145. You can also use the contact page to send your requirements.