Horizontal foam cutting machine - PARK and PPAB

TL;DR: The horizontal foam cutting machine is used to cut a polyurethane block into thin sheets and patches of repeatable thickness, in continuous production mode. DZIERGWA produces two types of such cutters - PARK and PPAB - equipped with linear guides, pneumatic pressure and a belt conveyor, making them suitable for mass production of mattresses and sofa inserts.

What is a horizontal foam cutting machine

Horizontal foam cutting machine is a cutting machine in which a band knife cuts in a horizontal plane and the foam block is moved to the blade and cut into layers of a given thickness. Unlike vertical cutters, which divide a block into thick, standing slices, horizontal machines specialize in thin sheets and panels - from a few millimeters to several dozen - cut one by one from the same block.

Key design features include:

• linear guides - ensure stable, parallel knife guidance and repeatability of layer thickness;
• pneumatic pressure - keeps the block in a constant position, compensating for the elasticity of the foam;
• belt conveyor - automatically feeds material and receives finished sheets, enabling continuous operation;
• band knife with tension - guarantees a smooth, even cutting surface.

This arrangement allows you to obtain sheets of uniform thickness over the entire surface, which is critical where the foam layer is part of a larger product. You can find more information about the division into types in our guide to foam cutting machines.

Types of horizontal machines KNITTING - PARK and PPAB

DZIERGWA's offer includes two horizontal cutters, differing in their purpose and degree of automation.

PARK cutter

The PARK cutting machine is a classic horizontal machine for the production of sheets and panels. The foam block is moved under the band knife, and the operator (or controller) sets the thickness of subsequent layers. PARK is perfect where dozens of identical sheets are needed from one block - for example, mattress inserts, comfort layers or mats.

PPAB cutter

PPAB is a developed horizontal machine focused on continuous production. Thanks to the belt conveyor and automated material feeding, the line operates virtually without interruption, which translates into high efficiency in plants producing large-scale mattresses and upholstery inserts. You can find both machines in the [automatic machines] category(/en/oferta/maszyny-automatyczne).

Horizontal machine for cutting foam in the production of mattresses

The main field of application is the mattress and furniture industry. Horizontal foam cutting machine allows:

• cut the comfort layers of the mattress with precisely repeatable thickness;
• prepare inserts for sofas, corner sofas and armchairs;
• produce mats, underlays and technical sheets;
• process an entire block into a series of slices without downtime.

Repeatability is key here - a mattress composed of several layers of foam requires that each layer be of the same thickness. The cutting precision of DZIERGWA machines is in the range of ±1–2 mm, which eliminates waste resulting from dimensional discrepancies in mass production. We write more about cutting foam for upholstered furniture in a separate article on cutting foam for furniture.

Horizontal or vertical - which one to choose

The choice between a horizontal or vertical machine depends on the final product:

• horizontal machine (PARK, PPAB) - when you need thin sheets and panels, continuous production, large series of mattresses;
• vertical automatic (PPA) - when you cut a block into thick slices of a given thickness, up to 10 different thicknesses from one block in auto mode.

In many plants, both types of machines work in parallel, complementing each other. If you are hesitant about which technology to choose, it will be helpful to compare vertical and horizontal machines. It is also worth looking through the offer of manual machines if the production scale is smaller.

Automation and control

DZIRGWA horizontal machines can cooperate with control systems that set the layer thickness and synchronize the operation of the conveyor. Thanks to this, the operator sets the parameters and the machine performs the cycle repeatably and safely. The pneumatic pressure and tension of the knife minimize vibrations, and the belt conveyor reduces manual handling of heavy blocks, increasing safety and work speed.

As a result, the line based on PPAB allows for all-day, efficient production of sheets without loss of cutting quality, which is the foundation of profitability in mass production of mattresses.

Benefits for the production plant

• high efficiency - continuous operation and automatic material feeding;
• repeatability - uniform sheet thickness throughout the series;
• lower waste - precision of ±1-2 mm reduces waste;
• less manual work - the belt conveyor relieves the operators' workload;
• versatility - from thin mats to thicker comfort sheets.

Summary and contact

Horizontal foam cutting machine is the basic tool of every plant producing mattresses and upholstery inserts. PARK and PPAB cutting machines from DZIERGWA combine precise cutting, automation and continuous production efficiency. Do you want to choose a machine for your production line? Contact us - we will help you choose the PARK or PPAB model to suit your needs and production volume.