Continuous Foaming Machine (CFM500 / ULTIMA): High-Capacity Foam Block Production Redefined

In the competitive world of PU foam manufacturing, the ability to produce high-volume, consistent quality foam blocks is a game-changer. The CFM500/ULTIMA continuous foaming machine from A.S. Enterprises addresses exactly this challenge, offering manufacturers the performance, automation and yield required for modern foam production.



What Is the CFM500 / ULTIMA Continuous Foaming Machine?

The continuous foaming machine is designed for large-scale production of flexible polyurethane foam blocks, using a continuous slab flow process rather than traditional batch systems. The model designated “ULTIMA” (also referred to in some resources as CFM500) features a robust production rate and advanced process controls. ([A S Entterprises][1])

Key specifications include:

  • Maximum output up to 350 kg per minute. ([A S Entterprises][1])

  • Fresh foam yield up to approx. 92%. ([A S Entterprises][1])

  • Wide density range (for example, densities from 9 to 60 kg/m³) and flat-top block format. ([A S Entterprises][1])

  • PLC/touch screen control, with online formulation storage and recall, and optional density/colour change-over. ([A S Entterprises][1])

Why Choose the CFM500 / ULTIMA for Foam Production?

1. High Production Throughput Producing 350 kg/min enables large manufacturers to scale quickly and meet high demand with fewer production lines. This capacity supports bedding, furniture, automotive seating and other high-volume foam applications.

2. Excellent Yield & Material Efficiency With fresh foam yields of up to ~92%, the machine helps reduce waste. Higher yield means more usable block material per kilogram of raw chemicals, improving profitability and sustainability.

3. Automation & Process Control The advanced PLC/touch-screen interface allows precise control of chemical dosing, block dimensions, inline adjustments and formulations. Online density and colour change capability make the line more agile for model or specification changes.

4. Flat Top Block Format Flat-top foam blocks simplify downstream cutting, laminating and processing. They align well with horizontal or vertical cutting machines, conveyor systems and block-processing lines.

5. Cost & Waste Reduction Improved yield + automation + fewer manual interventions = lower operating cost per unit. Less wastage also supports sustainable manufacturing initiatives.

Applications Across Foam Manufacturing Segments

The CFM500 / ULTIMA continuous foaming machine is suitable for multiple foam production contexts:

  • Bedding & Furniture: Foam blocks for mattresses, cushions, upholstered furniture

  • Automotive & Industrial: Seating cores, insulation foam, acoustic foam elements

  • Packaging & Specialty Foam: Large-scale production of foam blocks for die-cut packaging or protective components

Manufacturers looking to upgrade from batch systems, or expand into higher capacity production, will find this machine especially relevant.

How to Assess If the CFM500 / ULTIMA Fits Your Factory

Before purchase/installation consider:

  • Floor space and utilities: The machine will require a significant footprint (e.g., space requirement ~50 m × 6 m in certain specs) and power supply (e.g., ~120 kW) for full-scale output. ([A S Entterprises][1])

  • Block size and downstream integration: Ensure the block width and downstream conveyors/horizontal cutting machines match your production requirements.

  • Density/specification flexibility: If you produce high densities or need frequent changeovers, confirm the machine’s capabilities.

  • Automation level & ROI timeline: Higher automation often means higher upfront cost but provides quicker ROI via lower labour, waste, and higher throughput.

  • Support & servicing: Choose a manufacturer with strong service support, spare parts availability, and global experience.

Why Partner with A.S. Enterprises?

A.S. Enterprises is a recognized leader in foam machinery, with decades of experience and many installations globally. Their continuous foaming machines like the CFM500 / ULTIMA represent industry-leading design, reliability and performance.

By selecting their equipment, manufacturers gain access to proven technology, strong after-sales support, and the ability to scale production with better economics.

Conclusion

For foam manufacturers seeking to build or expand a modern foam production line, the CFM500 / ULTIMA continuous foaming machine from A.S. Enterprises offers a compelling solution. High capacity, excellent yield, automation and flexibility combine to make it a future-ready investment.

If you’re aiming to increase output, improve quality and optimize costs in your foam manufacturing operations, this machine is worth exploring in detail. Visit the product page at A.S. Enterprises to request a quote and technical brochure.

👉 Explore CFM500 / ULTIMA Continuous Foaming Machine here

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