The first question every foam workshop asks when it stops buying slab is the same one: how much foam can the machine actually make per batch? The answer decides the drum inventory, the mold table, the shift plan, and the size of the factory it can feed, and getting it wrong means either a machine that sits idle or a foam room that cannot keep the cutting line fed. The IF-FV01/02 Manual Vertical Foaming Machine answers the question with two capacity tiers: the IF-FV01 charges 150 kilograms of foam per batch on an 11-kilowatt drive, and the IF-FV02 charges 180 kilograms per batch on a 15-kilowatt drive, both mixing at up to 3,000 revolutions per minute with high-speed and low-speed stirring in a vertical tower layout. A batch is the unit the whole foam room is planned around: 150 or 180 kilograms of raw material charge becomes one molded block, and with two molds cycling, one operator runs four to six batches per shift, which is 600 to 1,080 kilograms of sponge per day. This guide works through the capacity math, the high-low speed stirring cycle, and the selection model that tells a growing workshop which tier to buy first.
Foam capacity is measured in batches, not in machine speed, because the batch is the unit that ties the chemistry to the mold and the mold to the shift. A vertical foaming machine takes one weighed charge of polyol, isocyanate, water, and catalysts, mixes it to a full reaction in the foaming bucket, and pours it into a mold where it rises into a block. The IF-FV01 does that with 150 kilograms per charge and an 11-kilowatt drive; the IF-FV02 does the same with 180 kilograms and a 15-kilowatt drive. The factory does not choose a machine, it chooses a batch size, and the batch size must cover the largest mold the cutting room wants to fill in one pour, because a mold cannot be topped up mid-rise.
The selection rule is built on the monthly foam budget. A factory that consumes eight metric tons of foam per month runs roughly 45 batches of 180 kilograms, or 54 batches of 150 kilograms, and the smaller batch size simply means more batches in the month, not less foam. The real difference appears in the daily rhythm: with two molds cycling, the 180-kilogram tier produces about 1,080 kilograms per shift on four batches, while the 150-kilogram tier produces about 900 kilograms on the same shift plan, so the 180-kilogram machine is the choice for a factory that wants one shift to cover a full month's consumption with room for growth, and the 150-kilogram machine is the leaner entry point that still feeds a cutting line doing 300 to 400 mattresses per month.
The vertical layout changes the economics of the foam room itself. The IF-FV01/02 stands in a tower configuration roughly 3 meters high, which puts the mixing bucket at a height that lets gravity do the pouring: the charge flows from the bucket into the mold on the floor instead of being carried across the room, so the same operator moves less and the batch cycle stays tight. The footprint is a fraction of a horizontal mixer with the same capacity, which matters in existing factories where the foam room is a converted bay, and it leaves floor space for the drum storage and the mold table that the batch plan requires.
The upgrade path is what makes the two-tier line a safe first purchase. A workshop that starts with the IF-FV01 at 150 kilograms keeps the same drum stock, the same scale, the same batch sheet, and the same operator when it later adds an IF-FV02 for the second shift, because the chemistry is identical and only the charge weight changes. The IF-FV01/02 Manual Vertical Foaming Machine is therefore not a one-shot bet on a batch size, it is a platform that grows from 150 kilograms to 180 kilograms and from one machine to a battery of machines without changing the foam room's procedures.
The quality of a foam block is decided in the first minutes of the batch, and the stirring profile is the tool that decides it. The IF-FV01/02 mixes each charge in two phases: low-speed stirring blends the polyol, isocyanate, water, and catalysts into a uniform liquid without whipping air into the charge too early, and high-speed stirring, up to 3,000 revolutions per minute, drives the dispersion that makes the cell structure even. The two phases run on the built-in timing function, so the operator sets the seconds for each phase on the recipe sheet and the machine holds them batch after batch.
The vertical tower then does the pour. The mixed charge sits in the foaming bucket at the top of the tower, the mold sits on the floor beneath it, and the operator opens the discharge so the charge flows straight into the mold, which avoids the long transfer that horizontal machines need and keeps the reaction clock honest: the charge is in the mold in seconds, not in a ladle on the way across the room. The foam rises in the mold over the following minutes, sets, and demolds after the recipe's cure time, and the block goes to the cutting room with the same dimensions batch after batch.
One operator runs the whole cycle with two molds. While one mold cures, the operator weighs the next charge, runs the low-speed and high-speed phases, and discharges into the second mold, so the mixer is never waiting on the chemistry and the chemistry never waits on the operator. The vertical layout keeps the weighing station, the bucket, and the mold table within reach of one work position, which is why the documented output of the tier holds up in practice: four to six batches per shift with a single operator, and the second shift simply repeats the same sheet.
The IF-FV01/02 is delivered in two tiers that share the same tower design, the same control panel, and the same foaming buckets. The table below summarizes the technical data for both models, so the selection can be made on one page.
Installation takes one day in an operating factory. The tower needs a level bay with headroom above 3.1 meters, roughly 12 to 18 square meters when the drum storage and the mold table are included, and a power supply for the 11- or 15-kilowatt draw. The foaming room should hold 20 to 30 degrees Celsius, because the rise time of the recipe follows the room temperature, and the discharge area under the bucket must stay clear during the pour, which the SOP below enforces.
The model below follows a workshop that currently buys slab foam at ~$2.30 per kilogram and consumes roughly eight metric tons per month, which is the scale where in-house foaming becomes the obvious move: eight tons is about 45 batches of 180 kilograms, or about two batches a day on a lean shift plan. The projection assumes the IF-FV02 at 180 kilograms per batch, one operator, two molds, and a single shift of 22 working days.
IF-FV01/02 Manual Vertical Foaming Machine: foaming output of 150 kg per batch on the IF-FV01 and 180 kg per batch on the IF-FV02, foaming bucket diameters of 450 and 500 mm, maximum mixing speed of 0 to 3,000 revolutions per minute, total power of 11 kW on the IF-FV01 and 15 kW on the IF-FV02, machine external size of L1400 x W950 x H3000 mm for both tiers, high-low speed stirring with a built-in timing function, vertical tower layout with gravity discharge straight into the mold, manual chemical charging with one operator, one-day installation in an operating factory, bay of 12 to 18 square meters including drum storage and mold table, headroom above 3.1 meters, 20 to 30 degree Celsius operating room temperature, and compatibility with the IF-FF2 bench-top foaming machine and the Foam Chemicals & Binder raw material program.
The model assumes the recipe is stable from the first month, so the payback band of 4 to 6 months absorbs the training ramp, where the first batches carry scrap while the operator learns the two-phase timing and the density drifts with the room temperature. After the ramp, the saving compounds, and the platform grows: a second machine on the same sheet doubles the batch count without changing the procedures, which is the difference between buying a mixer and building a foam department.
The question of how much foam a vertical foaming machine can make per batch is really a question about the shift plan, the mold table, and the drum inventory, and the IF-FV01/02 answers it in two tiers that share one platform. The IF-FV01 charges 150 kilograms on 11 kilowatts, the IF-FV02 charges 180 kilograms on 15 kilowatts, both mix at up to 3,000 revolutions per minute with high-low speed stirring and a timing function, and the 3-meter tower pours the charge straight into the mold, so one operator keeps four to six batches a day on the floor.
The decision rule for a growing workshop is simple: match the batch size to the mold, match the machine to the monthly foam budget, and keep the upgrade path open. If the foam room needs about 900 kilograms per shift, start with the IF-FV01; if it needs 1,080 and wants room to grow, take the IF-FV02; and either way the second machine can join the same sheet when the cutting line asks for it. Plan the batch, pick the tier, and the foam room stops buying slab and starts making its own material, with the payback in the ledger inside six months.
Contact our foam machinery engineers today for a capacity review of your monthly foam budget, a batch plan for 150 or 180 kg molds, the raw material list and costing sheet for your target density, and a factory-direct quotation for the IF-FV01/02.
