Hennecke has expanded its offering in continuous slabstock polyurethane block foam production with the Smartflex evo line. Positioned between the compact Jflex evo and the high-output Multiflex, Smartflex evo is aimed at manufacturers seeking a cost-effective entry into larger-scale production of comfort foams for mattresses, upholstered furniture and related home applications. The concept combines a modular, space-saving plant design with standard high-pressure dosing of all isocyanates, an indirect liquid laydown arrangement and process features intended to reduce waste and improve raw material yield. The system is specified to process up to eight polyols, three isocyanates and 24 additives, and is supplied with the Foamware Slabstock control software running on a Simatic industrial PC. According to the company, the technical parameters, particularly viscosity and discharge capacity ranges, were defined to cover typical application scenarios while maintaining an attractive balance between performance and investment costs.
Positioning and target applications
The Smartflex evo closes a gap in Hennecke’s slabstock range between Jflex evo, designed for small to medium outputs, and Multiflex, positioned as a high-productivity benchmark. "With the Smartflex evo, we offer our customers a solution that combines all the key design and technological advantages gained from more than 70 years of experience in continuous block foam production. At the same time, the system enables foam producers in the furniture and mattress industry to enter larger production volumes at an attractive price," said Svend Weidemann, president of the Hennecke Business Unit Germany. He added: "This gives us attractive access to large-scale foam production, efficient, functional and future-oriented."
Smartflex evo is configured specifically for comfort foams. "For technical foams, as we define them, Multiflex or Qfm continue to be the recommended systems," said Dr Joachim Berthold, senior director sales slabstock lines. "For users in the comfort segment, however, Smartflex evo is a perfectly tailored solution offering high efficiency and proven Hennecke quality."
Process and application technology
High-pressure dosing of all isocyanates is standard in Smartflex evo. "Precise high-pressure dosing is an integral part of the Smartflex evo and ensures optimum raw material utilisation and excellent foam quality," said Dr Florian Thiebes, team leader mechanical design slabstock. Compared with low-pressure systems, Hennecke reports savings of up to four percent isocyanate. The line uses an indirect liquid laydown, routing material via a short flexible hose from a fixed mixer to the application table. The Mixguide non-return valve, described as a moving paper guide, prevents backflow and promotes a homogeneous foam reaction across the full foaming width. This feature is intended to reduce waste during recipe changes. Relative to trough systems, Smartflex evo targets significantly lower waste and reduced cleaning effort when changing formulations.
SmartFlex evo – the economically attractive entry point into large-scale production of comfort foams
Modular design, footprint and productivity
The plant concept follows a highly modular and standardised approach, with a compact configuration and without a classic portal, which reduces overall height and can benefit sites with limited ceiling clearance. Modularisation is intended to shorten delivery and commissioning times, including transport of larger pre-assembled modules to reduce on-site assembly. The line includes dosing pump units matched to common viscosities and discharge ranges, new Smartjector feed devices and optional computer-monitored volume flow measurement for safety-relevant components. Standard manually tiltable side walls, optionally motorised, enable precise adjustment to different foam types and, together with the standard Flat-top device, can produce an almost rectangular block profile. This supports lower trimming waste and improved raw material yield. An ergonomically optimised operating platform is designed to improve access around the mixer for production and maintenance.
Control and data management
All new Hennecke block foam systems, including Smartflex evo, are equipped with the Foamware Slabstock visualisation and control software on a Simatic industrial PC. The package supports fast commissioning, process control, production data management and remote maintenance. Optional extensions include block height and foam profile measurement with additional sensors for enhanced process reliability.
"We defined the technical parameters, particularly with regard to viscosity and discharge capacity, in such a way that they cover a wide range of typical application scenarios," said Dr Florian Thiebes. "The result is a system that combines high productivity with efficient use of resources, and thus creates real added value for our customers." Summarising the positioning, Dr Joachim Berthold stated: "Our customers receive a state-of-the-art, efficient solution that opens up access to the market for premium comfort foams, while benefiting from the many technological strengths of Hennecke's state-of-the-art systems."
