Complete equipment inspection, parameter confirmation and material arrangement before formal packaging to ensure smooth operation.The touch screen will launch automatic system detection. Wait about two minutes until the screen displays System Ready.The machine is set to Manual Continuous Mode by default, which works well for scattered and non-standard products. Choose Fixed Time Mode for mass packaging of identical products. Switch to Mixed Time Mode if you need to handle multiple product specifications frequently. Assembly Line Mode is the optimal choice for assembly line production.
1. Machine Self-Inspection
Flip up the leakage protection switch on the right side of the main unit to power on the device.
2. Basic Parameter Confirmation
All core parameters are calibrated before delivery, so please do not adjust them casually in daily use. The temperature setting range for both Material A and Material B is 30-60℃, and the adjustable flow rate ranges from 2.5 to 4 kg/min. The standby flow rate is fixed at 2.00 kg/min as factory setting, and the standby pressure of Side A and Side B is within 0-6 KG. You may fine-tune the temperature and flow rate only when the working environment or raw material batches change. Meanwhile, check the material delivery hoses, foaming gun and gun cleaning box regularly, making sure the nozzle is unobstructed and the cleaning liquid is maintained at a normal level.
3. Material & Site Layout
Place Material A and Material B barrels steadily beside the machine. Keep the distance between raw material barrels and the main unit within 1.5 meters, and the distance between barrels and the foaming gun no more than 3 meters. Never insert Pump A and Pump B into the wrong barrels. Prepare dedicated packaging films in advance, keep the workbench tidy and reserve sufficient space for operation.
II. Main Packaging Method 1: On-Site Foaming Packaging (Universal Type)
This method requires no customized molds and offers flexible operation. It is applicable to products of various sizes and irregular shapes, and is widely adopted for warehousing, e-commerce and scattered goods packaging. Please follow the four steps below.
1. Lay Film & Apply Base Foam
Spread the high-strength dedicated packaging film evenly inside the carton, and attach the film closely to the box wall to avoid wrinkles and displacement. Hold the foaming gun and spray raw materials uniformly on the film at the carton bottom. Move the gun steadily while spraying to form an even cushioning base, for the mixed raw materials will react and expand rapidly.
2. Place & Position Products
After the base foam takes initial shape, put the product in the center of the foam and adjust its position. Ensure the product stays upright and does not touch the carton wall. You can spray a small amount of foaming material on sharp corners for reinforcement if necessary.
3. Cover Film & Apply Top Foam
Lay a new layer of packaging film over the product to fully cover the top and surrounding gaps. Spray foaming materials evenly on the film to fill the gaps between the product and the carton. The foam will wrap the product tightly to provide all-round shock absorption and protection.
4. Seal Carton & Clean Up
Wait until the foam fully expands and cures. Tidy up the excess film and close the carton. After each packaging task, clean the nozzle by dipping the foaming gun into the cleaning box to prevent raw material solidification and nozzle clogging.
Practical Tips
Do not spray new foaming material onto expanding foam, as it will damage the internal structure of the foam and reduce its cushioning performance. Control the spraying volume properly and reserve enough space for foam expansion to prevent overflow. Make sure the packaging film separates products from foaming materials completely to avoid adhesion and contamination.
III. Main Packaging Method 2: Mold-Based Preformed Foaming Packaging (Mass Production Type)
This process is designed for mass production of identical products on assembly lines. It can produce foam cushions with consistent specifications and greatly improve working efficiency, ideal for home appliances, hardware, precision instruments and other standardized products.
1. Make Simple Molds
Fabricate wooden simple molds according to the shape and size of products. Ensure the inner cavity of the mold fits the product contour perfectly, and the mold can open and close smoothly for easy demolding. Place the mold steadily on the workbench.
2. Lay Film, Inject Material & Close Mold
Line the inner cavity of the mold with packaging film, and make sure there are no wrinkles or displacement. Inject foaming materials evenly into the mold, then close the mold cover immediately. The polyurethane materials will react quickly and form integrated foam cushions within seconds.
3. Demold & Pack in Batches
Open the mold after the foam is fully cured and take out the finished foam cushions. Put one foam cushion at the bottom of the carton, place the product inside, and use another cushion to wrap the top and sides of the product to complete packaging. You can reuse the same mold continuously to produce cushions for identical products in batches.
Practical Tips
The mold will heat up after repeated use, and foam will expand to a larger volume in a hot mold. If you use Fixed Time Mode for mass production, please reduce the spraying time by 5% for hot molds to keep the foam size consistent. Adopt Fixed Time Mode in mass production to unify spraying duration and minimize manual errors. Remove residual foam from the mold after each demolding to avoid affecting the forming effect of subsequent products.
IV. General Operation Rules & Quality Control
1. Universal Operation Rules
Carry out regular nozzle cleaning after every spraying work. Clean the foaming gun in the dedicated cleaning box each time. Keep the cleaning liquid level 2 millimeters above the top of the steel brush, and replace worn or deformed steel brushes in a timely manner to prevent nozzle clogging fundamentally.
Follow the rules for raw material use strictly. Never operate the pumps when the barrels are empty. Insert and remove pumps quickly when replacing raw material barrels. Do not leave pumps exposed in the air for a long time, otherwise the raw materials will harden and cause permanent damage to the pumps. Always match Pump A with Material A and Pump B with Material B.
Comply with working environment requirements. Keep the ambient temperature between -8℃ and 45℃, and relative humidity between 5% and 90%. Abnormal temperature and humidity will affect the foaming speed and overall quality of foam.
2. Troubleshooting for Common Issues
If the foam looks pale and soft, and shrinks after forming, it is usually caused by excessively high temperature of Material B or a clogged filter of Pump A. Just lower the temperature of Material B and clean the filter of Pump A.
If the foam turns dark, hard and brittle, check whether the ambient temperature is lower than 15 degrees Celsius. Raise the working temperature, and clean the nozzle and filters thoroughly.
When raw materials splatter during spraying, there may be solidified residue on the nozzle or the flow rate is set too high. Clean the nozzle and appropriately lower the flow rate to solve the problem.
If raw materials leak from the foaming gun, the nozzle may be loosely installed or misaligned, or the O-rings and sealing parts are aged and deformed. Reinstall the nozzle correctly and replace all damaged sealing accessories.
V. After-Sales Support
The CosMolar CM-811 semi-automatic foaming machine supports both scattered packaging and mass production with two practical packaging solutions. Standard operation can help you achieve efficient and stable packaging work.
If you encounter any problems about equipment operation, parameter adjustment, troubleshooting or mold customization, please feel free to contact us. Our service hotlines are 400-812-0328, 0755-27807490 and 13798439218. Our address is Building B2, Buxin Second Village Industrial Zone, District 74, Xin'an Street, Bao'an District, Shenzhen. You can also visit our official website: http://www.CosMolar.com.
As a professional brand dedicated to the research and development of foaming new materials and packaging equipment, CosMolar provides one-stop services including professional technical guidance, equipment maintenance and consumables supply. We help enterprises optimize packaging procedures and reduce product damage during logistics transportation.
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