POLYURETHANE FOAM MIXER & MANIFOLD DESIGN

A Guide for the Foam Chemist & Process Engineer

DECEMBER 31, 2020

CUSHMAN ENGINEERING, INC.
1138E 1050N, Ossian, Indiana 46777 USA
 Foam Machine Mixing and Manifold Design
Contents:
Part 1: Polyurethane Foam Manufacture, Mixer and Manifold Design ..............................................................................................2
The Basic Polyurethane Foam Chemical Reaction ..............................................................................................................................2
The Role of Catalysts and Surfactants: ..............................................................................................................................................3
Open Cell Foam: ................................................................................................................................................................................4
Order of Addition, General Rules: ......................................................................................................................................................6
Order of Addition, The Groups: ..........................................................................................................................................................6
Is Small Stream Mixing Necessary? ...................................................................................................................................................8
Order of Addition Mixhead Pictorial: .................................................................................................................................................9
Overall Rules of Manifold and Mixer Design:................................................................................................................................... 10
Milliken Reactint® Injection: A Special Case ..................................................................................................................................... 11
Milliken Reactints® Properties: ..................................................................................................................................................... 13
Why use water to purge? ............................................................................................................................................................. 13
Milliken System Schematic and Logic Explanation. An example of one color.................................................................................. 15
Three Mixing Legends:..................................................................................................................................................................... 16
Diamond Shaped Baffle Theory: ................................................................................................................................................... 16
Canted Pins Design: ..................................................................................................................................................................... 17
The Bull Cock Theory: ................................................................................................................................................................... 17
Drive Shaft Seal & Lubrication: ........................................................................................................................................................ 18
Part 2: Manifold and Piping Design.................................................................................................................................................. 20
Cavitation and Air Hole Problems: ................................................................................................................................................ 20
The Pinhole or Air Hole Question: ................................................................................................................................................. 20
Cavitation:................................................................................................................................................................................... 20
Examples of Piping Design Errors:.................................................................................................................................................... 22
Four inch & Five inch ∅ pipe polyol manifold, design errors:.......................................................................................................... 23
Improved Manifold Geometry: ........................................................................................................................................................ 25
Part 3: The TDI Manifold.................................................................................................................................................................. 29
The Utilitarian Value of the TDI Manifold. ....................................................................................................................................... 29
Figures:
FIGURE 1: BASIC FOAM REACTION ...................................................................................................................................................... 2
FIGURE 2: BASIC FOAM REACTION WITH CATALYSTS & SURFACTANTS ................................................................................................ 3
FIGURE 3: TRAVERSING LIQUID LAY DOWN OF POLYESTER. ................................................................................................................. 4
FIGURE 4: ORDER OF ADDITION & MIXING .......................................................................................................................................... 5
FIGURE 5: POLYOL MANIFOLD AND SMALL STREAM MANIFOLD PICTORIAL .......................................................................................... 7
FIGURE 6:ADDITION OF DYNAMIC MIXING IN SMALL STREAMS MANIFOLD .......................................................................................... 8
FIGURE 7: ORDER OF ADDITION MIXHEAD PICTORIAL .......................................................................................................................... 9
FIGURE 8: MILLIKEN REACTINTS® POLYOL FLOW OFF-LINE MANIFOLD ...................................................................................... 11
FIGURE 9: MILLIKEN REACTINTS® UTILIZING WATER FLOW IN AN OFFLINE MANIFOLD ................................................................ 12
FIGURE 10: MILLIKEN REACTINT® SCHEMATIC ................................................................................................................................. 14
FIGURE 11: MILLIKEN REACTINT® LOGIC ......................................................................................................................................... 14
FIGURE 12:THREE MIXING LEGENDS ................................................................................................................................................. 16
FIGURE 13: DRIVE SHAFT SEAL LUBE ................................................................................................................................................ 18
FIGURE 14: CLOSEUP: CORRECT SHAFT SEAL ARRANGEMENT ............................................................................................................ 19
FIGURE 15: POLYOL MANIFOLD TOO LARGE, DOWNHILL FLOW, AIR TRAPS ....................................................................................... 22
FIGURE 16: SHOWING AIR TRAPS AND BUTTERFLY VALVES ............................................................................................................... 23
FIGURE 17:DETAIL OF POLYOL MANIFOLD TOO LARGE FOR SMALL STREAM INJECTION ..................................................................... 24
FIGURE 18: DETAIL OF POLYOL MANIFOLD FLOWING INTO MIX CHAMBER ......................................................................................... 24
FIGURE 19: THE MODULAR POLYOL MANIFOLD ................................................................................................................................. 25
FIGURE 20: PLAN VIEW OF LOW VOLUME, MODULAR MANIFOLD....................................................................................................... 25
FIGURE 21: MODULAR MANIFOLD INSTALLED ................................................................................................................................... 26
FIGURE 22: MODULAR MANIFOLD COMPONENTS ............................................................................................................................... 26
FIGURE 23: WORCESTER DIVERTER VALVES BOLTED DIRECTLY TO MODULAR MANIFOLD MINIMIZES DEAD SPACE VOLUME.................. 27
FIGURE 24: 30 PORT SMALL STREAM MANIFOLD, 3” OD X 1½” ID HEAVY WALL TUBING .................................................................. 27
FIGURE 25: PROPOSED FIX USING ELEMENTS AS DISCUSSED .............................................................................................................. 28
FIGURE 26: TDI MANIFOLD EXAMPLE ............................................................................................................................................... 29
Page 1
Part 1: Polyurethane Foam Manufacture, Mixer and Manifold Design

Polyfunctional Toluene
Alcohol
Polyester, Polyether diisocyanate Water

Urethane CO2 Gas

Polyurethane
Foam

Basic PU Foam Reaction

Figure 1: Basic Foam Reaction
The Basic Polyurethane Foam Chemical Reaction
Actually two chemical reactions, TDI (Toluene Diisocyanate) is central to both. Polyol (short for polyfunctional
alcohol) combined with TDI creates elastomeric urethane. The combination of water and TDI produces CO2
gas. This reaction is exothermic. These two reactions taking place simultaneously produce foam. Polyurethane
foam is nothing more than urethane with bubbles in it. The French call it mousse.
Please refer to Dow Polyurethanes Flexible Foams1 for a complete study of the chemistry of polyurethane foam.

1
Copyright© 1997, by The Dow Chemical Company, pp 15-66
Page 2
 Polyfunctional Toluene
Alcohol
Polyester, Polyether diisocyanate Water

Tin Catalyst Amine Catalyst

Urethane CO2 Gas

Surfactant(s)
Polyurethane
Foam

Basic PU Foam Reaction

w/ catalysts & surfactants
Figure 2: Basic Foam Reaction with Catalysts & Surfactants
The Role of Catalysts and Surfactants:
A catalyst is a substance which changes the rate of reaction without becoming part of the reaction. Both the
polyol/TDI and water/TDI reactions are rather slow and lazy by nature. If these three ingredients were mixed and
left to stand without catalysis, the reaction is disappointingly slow. There is some incentive of the ingredients to
speed up the chemistry by the heat that is generated with the water/TDI reaction. Only a very small amount of
catalyst is necessary to get things going in the foam reaction.
The “gel” (polyol/TDI) reaction is typically sped up by adding what is called Tin. This is the element Tin in a
form which makes it readily available to the opposing molecules. The form is typically Stannous Octoate. Most
metals in the proper form will serve as a catalyst for this reaction.
The “blow” (water/TDI) reaction is typically sped up with an amine catalyst. Triethanolamine is an example. This
reaction generates heat (exothermic). It is not a massive amount of heat, but because the resultant foam is also a
thermal insulator, that heat cannot dissipate readily and causes the temperature of the foam to rise. As the water
level in a foam reaction is increased, more gas is generated, therefore lowering the density of the foam. Along
with additional gas comes additional heat. As the density of foam is lowered, its insulation value is increased,
there is less mass of foam to absorb heat, therefore the temperature can be dangerously high in very low-density
foams which are using elevated water levels to achieve that low density. The highest temperatures usually occur
about 30 to 120 minutes after the foam has been poured. Temperatures can increase to the point of degrading the
foam. This degradation is called “scorch” and it looks as though it has been toasted, exhibiting a yellowish or
brownish discoloration when cut open. Scorch can be so severe that the foam actually melts. Temperatures can
go high enough to ignite the foam while it is in storage. This is called auto-ignition.
Surfactants are exactly what the name implies; they work on the surface of the bubbles to adjust and control the
surface tension of the bubbles. When two bubbles are touching, they form an approximately round, thin membrane

Page 3
or window of urethane between them. There are no round windows in foam of course because there are never just
two bubbles. The windows in foam are pentagons and bubbles are virtually all dodecahedrons (12 sided). We will
call the thickened areas around the windows, struts.
Open Cell Foam:
This article is concerned with open cell foam, which is contrasted to pneumatic foam. Open cell foam is such that
as the bubbles of gas are expanding the urethane gel is strengthening, there is a point of balance at which the
windows among the many cells actually rupture or fracture in a way which allows gas to escape. At this precise
moment the cells are no longer relying on the pneumatic pressure of the gas to sustain their shape because there
is enough gel strength in the urethane struts all around the fractured windows to support the many cells.

Figure 3: Traversing Liquid Lay Down of Polyester.

In the foaming process, as the newly poured foam progresses along the conveyor, the gel and blow reactions,
spurred on by catalysts and some heat, are occurring with the balancing influence of the surfactant. Several
identifiable stages indicating the status of the quality of the foam being produced are observed.
Liquid poured directly on the conveyor has a very shiny surface and a deep or rich color if the foam is dyed or
pigmented.
Cream line: the liquid loses its sheen and that deep rich color begins to fade as the first tiny bubbles begin to form.
Cream line is a very important indicator of the health of a run and should be timed (and time recorded on the run
sheet) at every startup, whether it is liquid laydown as above or a trough pour. I acknowledge that measuring
cream time is difficult with the Variable Pressure Foam Machine.
Cream line can be seen in a trough pour (Maxfoam process), as the trough fills. Because the foaming liquid is
travelling vertically, rather than horizontally, as the trough is filled, the liquid phase and the cream line are
obscured shortly after startup. When the foaming liquid spills from the trough it is usually in the rising stage.
The next stage is rising foam, mostly supported pneumatically. This is the precarious balance between blow and
gel and surface tension. The ramifications of out-of-balance Tin, Amine and Surfactant are legion.
Rising foam reaches its full height and will shrink slightly as “health bubbles” appear. Health Bubbles; little holes
appearing in the thick top skin are venting gas escaping from all the windows fracturing at just the right time.

Page 4
 Polyol Manifold

Amine catalysts or blended "activator"

Polyol 1
Polyol 2 Surfactants
Polyol 3 Dyes & Pigments
Polyol 4
Other high viscosity Fire Retardant
high flow ingredients
Anti-Oxidant, Anti-microbial, UV inhibitor, Anti-static, etc.
Small Stream Manifold
Tin Catalyst
Polyol and all materials injected
upstream of this point are mixed
Location of tin injection point: 1st Stage
in Stage 1.
some chemists like to place the tin Dynamic Mixing
injector very close to the mix chamber
or in the mix chamber
Water injection point

Location of water injection point:

some chemists place this injector
upstream in the Polyol manifold
2nd Stage
Water and all materials Dynamic
injected upstream of this point are mixed in Stage 2. Mixing
1st and 2nd stages are important so that TDI
TDI injection point
is not selectively sprayed into
a concentrated stream of Water or other materal

Dwell Time = volume of mix chamber

from the point of TDI injection
to the last (bottom) pin on the agitator shaft 3rd Stage
divided by the throughput. Dynamic Mixing
Volume = cross section area of chamber
minus cross section area of agitator shaft
x the distance between TDI injection port
to last pin downstream.

P. U. Foam

PU Foam Reaction w/
complexities of mixing
and order of addition

Figure 4: Order of Addition & Mixing

Page 5
Order of Addition, General Rules:
Highest throughput materials first (farthest upstream away from the mix chamber), lowest throughput materials
last.
TDI always injected last (downstream of all other ingredients). The theory of injecting TDI last goes like this:
Get all ingredients evenly blended then inject the TDI which will begin both the gel and blow reactions
simultaneously, followed by additional mixing. It is important to keep TDI injection away from the shaft seal in
the mix chamber so it will not foul the seal and sleeve.
Order of Addition, The Groups:
Within the order of addition there are groupings of ingredients.
The POLYOLS are typically injected first and usually the polyol most frequently used or perhaps the polyol with
the highest viscosity is the first. Polyols are often blended and have a wide variety of throughputs depending on
the formulation. Sometimes fire retardants are included in this group. Frequently polyol manifolds are modified
for additional polyols and this is usually done in a way which puts the new polyol further upstream which may or
may not be a good idea.
The SMALL STREAM ingredients. There are so many. They are called SMALL because their throughput is very
much lower than the Polyols and they have small pipe diameters, small pumps, small tanks, etc. Usually there is
very little attempt to control their temperature because their low throughput, the thermal contribution is miniscule
compared to Polyols and TDI.
ISOCYANATES, WATER, TIN. These are in a special group because I find them being swapped around,
disregarding Order of Addition, General Rules above. Usually, the chemist who has done this will say,
“This is the way it has always been done,” or “I swapped the water and TDI injectors and it solved the problems
I was having,” I have no argument with pragmatism. I would, however, like to know why it works. Some say the
answer is that because the time difference between the TDI and Water injection is just a small fraction of a second
it makes no difference. Some things are unknown and unknowable. When I encounter a foam machine which has
its TDI injection point upstream from other injection points, I find badly fouled injectors downstream and usually
a very frequent seal problem on the mixer shaft because the TDI injector is forcing liquid TDI up into the shaft
seal area. One of the difficulties with Tin is that it hydrolyzes and becomes less efficient or completely useless.
This apparently happens quickly.2 A chemist might say: “I moved the Tin injector into the mixhead and the
problem went away.” Again, pragmatism.
MILLIKEN REACTINTS®: Reactints® are a special case and I have put an effort over the years to extract the
best performance from them. Milliken Chemical has also put a large effort into assisting their customers use their
products by designing and providing equipment for the purpose. Milliken Chemical is to be commended for this
effort. Early on, Reactints® were plagued with serious problems such as very slow startup, long changeovers and
very messy shutdowns and frequently off color. These problems were solved through a methodical correction of
bad design in the early delivery systems and the institution of the “Offline” manifold. An in-depth study is found
in Milliken Reactint® Injection: A Special Case page 11

2
Patrick DeMeyer, Chemist, Recticel in Wetteran, Belgium
Page 6
 MNSS
USA
XXX
Poly Injection Ports

MNSS
USA
XXX
Side Entry Only

MNSS
USA
XXX
Small Stream Injection Ports
Straight Through of Various diameters
Poppet Style Injectors either

MNSS
USA
XXX
Handle or Screwdriver Adjustable
Injecting horizontally into vertical downward flow.

MNSS
USA
XXX
Figure 5: Polyol Manifold and Small Stream Manifold Pictorial

Page 7
Is Small Stream Mixing Necessary?
Yes. One of the difficulties in the small stream
manifold is that almost all the materials added are at
very low flow rates relative to the main polyol flow.
Remember there is no mixing because all flow in the
manifold is laminar. At the point of injection, the
small stream encounters the main polyol flow and
almost immediately has all its momentum dissipated. Servo Motor

The resultant is the small stream is then found

clinging to the inside wall of the manifold and just
creeping along at whatever the boundary layer
velocity is, which is almost zero.
Small stream manifold dynamic mixing: The
addition of a mixer shaft with servomotor drive and
the standard shaft seal will completely blend all the
injected polyols and other high viscosity liquids from
upstream with each small stream as each is injected.
The blending will be forced and complete regardless
of differences in throughput, specific gravity or
viscosity.

MNSS
USA
XXX
There is no chance of the low flow, high viscosity
materials to “lump” up on the inside wall of the

MNSS
manifold as this mixer forces turbulence.

USA
XXX
This method of mixing is superior to the static mixer.

MNSS
USA
XXX
The static mixer is not moving and therefore provides
addition surface area for the higher viscosity, low

MNSS
USA
XXX
flow materials to accumulate and stall

MNSS
USA
XXX

Figure 6:Addition of Dynamic Mixing in Small

Streams Manifold

Page 8
 0.6" minimum NO PINS!

1st Stage
Mixing

XRT250
USA
XXX
2nd Stage
Mixing

XRT563
1" minimum NO PINS!
USA
XXX

Water injection

TDI injection
9.412in
dwell 3rd Stage
length Mixing

Ø3.000in
Ø1.500in
Sample Dwell Time Calculation Annular Cross
Section
Area = 5.3in²
Volume: 9.412in x 5.3in² = 50in³ = 0.82 liter

Throughput: 90L/min = 1.5L/second

Dwell Time: 0.82L ÷ 1.5L/second = 0.55second

Figure 7: Order of Addition Mixhead Pictorial

Order of Addition Mixhead Pictorial:
Figure #7 above, is the actual drawing of a custom designed mixing system in use.
There have been and still are just a few foam machines which have the flow through the mixing chamber from
down to up. I have never designed a mixer in this way. The main advantage of this scheme is that air is purged
from the injection manifolds and mix chamber quite readily.
The Problem: With the shaft seal at the bottom of the mix chamber and the TDI injector just above it, TDI
infiltrates into that shaft seal when the foam run is complete and all ingredients are in the recirculate mode.
Invariably, TDI will either drip or run down onto the shaft seal, making a hard surface of urea on the shaft, the
seal and even below the seal. The seals are therefore in need of replacement frequently which is a very difficult
process in that maintenance personnel must work from under a platform, etc. which has been fowled with dripping
and running chemicals including TDI. These leaked fluids are very destructive to the power transmission
components which turn the drive shaft. Motor, coupling, pulleys, belt, shaft encoder, etc. are usually coated with
all manner of chemicals which have gotten past the seals.

Page 9
The Solution: With vertically downward flow, gravity eliminates the TDI/seal problem. The major remaining
problem is how to purge the air from the injection manifolds and the mixing volumes. This purge is readily
accomplished by correct sizing of these components. That is, they must be relatively small in diameter and length.
Overall Rules of Manifold and Mixer Design:
The mixing portion should have vertically downward flow. “Always use gravity whenever possible, it is cheap
and reliable.”3
Maintain inside diameters to a minimum. Provide enough pump motor power to overcome higher pressures. The
goal is to shorten time in the manifold and encourage any air bubbles to keep moving downstream with the flow.
Maintain minimal distances between injection points. With minimal length and diameter in order to minimize
volume. Minimized volume works advantageously minimizing start-up and formulation changeover lengths and
shutdown/flushing mass. Therefore, foam scrap, liquid waste and hazardous waste are all reduced.
Dwell time as shown in Figure #6, is measured from the point of TDI injection to the last (bottom) pin on the
agitator shaft. It is defined as the time taken for the combined throughput of the ingredients to traverse this
distance.
Volume
Time = Throughput
Liters
Seconds = Liters
/Second

Most foam machines are operating with a dwell time of approximately 0.5 second to 1.0 second. The amount of
mixing can be varied by adjustment of the mixer speed. In general, mixing more than the minimal necessary to
yield good product runs the risk of fracturing polymer chains.

3
Dr. W. Edwards Deming, Quality Enhancement Seminar, Minneapolis, MN. May 21-24, 1990
Page 10
Milliken Reactint® Injection: A Special Case
Main Polyol 3-way Dispense Valve

Mixhead
Port Ring

Milliken Injection proposed method

1. Swagelok 3-way ball valves
2. Straight through style injectors custom made
3. Or poppet style screwdriver adjust MNSS
Black 4. Or poppet style handle adjustable XRT250
N
O

N
C
N
C

Blue

N
O
Violet
N
O

N
C
N
C

Yellow
N
Orange O
N
O

N
C
N
C

Red
N

injector
O

Pressure
NO NC Pressure
Transmitter
Switch

Pressure
Pressure
Transmitter
Switch

Polyol (low flow)

metering pump

Figure 8: MILLIKEN REACTINTS® Polyol Flow Off-Line Manifold

Page 11
 Mixhead
Port Ring

Milliken Injection method

1. Swagelok 3-way ball valves
2. Straight through style injectors custom made
3. Or poppet style screwdriver adjust MNSS
Black
N
O

N
C
N
C Blue

N
O
Violet
N
O

N
C
N
C

Yellow

N
O
Orange
N
O

N
C
N

Water 3-way
C

Red
N

Dispense Valve injector

O

Pressure
NO NC Transmitter
Pressure
Switch

Pressure
Pressure
Transmitter
Switch

Water metering pump

Figure 9: MILLIKEN REACTINTS® Utilizing Water Flow in an offline manifold

Page 12
Milliken Reactints® Properties:
Reactints are true dies. They are liquid. Contrast to pigments; which are solids, roll milled to a specific diameter
then dispersed in a liquid.
Milliken Reactints® are fundamentally polyester polyols. They have the quality of being soluble in other
polyesters, polyether polyol and water.
Reactints® react with TDI the same way other polyols do. The solids in pigments do not react with TDI.
Reactints® are not solids dispersed in liquid, they will not settle or increase the number of nucleation sites which
is frequently a disadvantage of pigments.
Reactints® are transparent. That is; light passes through them and is filtered as it does. Pigments, conversely, are
opaque and reflect certain wavelengths depending on the color of a pigment. For example; something which
appears to be blue is actually absorbing all wavelengths of light but the blue. You might say that Reactints® are
refractive and pigments are reflective. In a pigmented foam, the pigment which you are seeing is only on the very
outside of the surfaces you can see. In foam dyed with Reactint®, you are seeing light which has passed through
or deeply into the structure of the foam. This is why only a very small amount of Reactint® is needed, compared
to pigment.
The high concentration of Reactint® dyes requires very low flow rate metering pumps.
A few necessary rules have been developed to help the Foam Chemist and process engineer yield the best
performance from Reactints®. Figures #7. #8, #9 & #10 as a guide.
Constant temperature is necessary because the viscosity of Reactints® varies greatly by temperature. Viscosity
variation effects gear pump performance radically, causing off color problems, striations, etc.
Constant pressure is required to prevent long startups and changeovers because of color bleed, fade, motor ramp-
up delays, etc.
The off line manifold is necessary to introduce color into the small stream manifold rapidly.
Do not use Polymer Polyol (copolymer, etc.) as the purge fluid!
Why use water to purge?
Reason #1: Reactints® are water soluble.
Reason #2: Water is required in all foam formulations.
Reason #3: If you have two mix chambers, such as the case with a conventional mixer and a CO 2 mix chamber,
it is a simple matter to transfer that one water injector from one mix chamber to the other negating the need to
move multiple color injectors.

Page 13
 Equipment within the dashed line
Back Pressure Regulator is mounted compactly on a "PUMP STAND"
Maintain 80 to 100 PSI.

High Throughput
Gear Pump

Ener. De-En
A
Mixhead
Medium Throughput Port Ring
Gear Pump

Ener. De-En
B
Low Throughput
Gear Pump

C
Black

D
e-
En

N
C
En
er
Blue

N
O
In Line Heater or
Violet

N
Heat Exchanger

N
Maintain 100°F

C
N
C
Yellow

N
O
Orange

N
O
Pressure Pressure

N
Pressure Pressure

C
Transmitter Transmitter

N
Switch Switch

C
Red

N
injector

O
NO
NC
Water 3-way
Dispense Valve
Water metering pump

Figure 10: Milliken Reactint® Schematic

Solenoid "A" Solenoid "B" Solenoid "C"

Solenoid
Mode

Energized

Energized

Energized

Energized

Energized

Energized
De-

De-

De-

Flow Mode
High Flow Maintain X X X
High Flow Dispense X X X
Medium Flow Maintain X X X
Medium Flow Dispense X X X
Low Flow Maintain X X X
Low Flow Dispense X X X
Figure 11: Milliken Reactint® Logic

Page 14
Milliken System Schematic and Logic Explanation. An example of one color.
Multiple pumps shown in Figure #10, two or three, are required to accommodate the wide range of flows.
In Figure #11 above “Maintain” refers to flow of constant pressure and temperature through the entire pipe run
through valve “C” and back to the day tank. “Dispense” means color flowing into the manifold through valve
“C.” Valves “A” and “B” determine which pump will be the metering pump for a specific formula. Low Flow
pump is always contributing.
All pumps in each system are turning at an elevated throughput, recirculating constantly through the entire piping
system maintaining constant pressure and temperature. There is no need for a separate piping run for each pump
size. I have seen this; it is a bad idea. A separate motor is recommended for each pump. The seemingly good idea
of one motor and three pumps is also a bad idea, proven by experience.
The PLC will select which of High or Medium solenoids are energized or de-energized at the moment of dispense
and the moment of maintain. Pump speed will be changed to the setpoint to accommodate the recipe. Low flow
is always contributing to the throughput of all recipes. This is so that when Low flow is neat there is no delay in
its dispensing.
Although this seems to be an unnecessarily complicated way to introduce dyes into a foam machine mixhead, it
has been shown to be an effective solution to overcome the inherent problems associated with the required low
flow rates4.

4
Early on, Reactint®s were plagued with serious problems such as very slow startup, long changeovers and very
messy shutdowns and frequently off color, color striations, etc.
Page 15
Three Mixing Legends:

XRT250
USA
XXX
Diamond Shaped
XRT563

USA
XXX

Baffle

Pins Canted 3°

Bull-Cock

Figure 12:Three Mixing Legends

Diamond Shaped Baffle Theory:
The Diamond Shaped Baffle prevents TDI from progressing upstream and contaminating the shaft seal and other
injectors above the baffle. It probably does this.
An unintended benefit; there probably is some mixing occurring around the narrow annular gap between the mix
chamber ID and the diamond OD. Agitators made this way usually do not have pins above (upstream of) the
Diamond Shaped Baffle.
Page 16
Conversely, any pinching of the cross section will increase velocity at the pinch and increase the pressure up
stream.
The installation of the Diamond Shaped Baffle precludes the use of stator pins.
The space immediately above the Diamond Shaped Baffle is potentially a centrifugal refuge for accumulating
“Air.”
Canted Pins Design:
The Canted Pin Design predates my experience (1976) and was at that time entrenched. The first time I saw
straight pins was on the Maxfoam machine purchased by Scott Paper Foam Division in 1977.
The Canted Pin design also precludes the use of stator pins but theoretically eliminates the need for stator pins. I
personally favor stator pins. One of the benefits of stator pins is that the swirling motion imparted in the liquid
pouring from the outlet is greatly reduced or eliminated. Stator pins increase mixing in the same volume.
There is an old debate about pin shape. Some like round pins, others flattened (screwdriver shaped) pins. I have
designed all kinds and can’t really say that one is superior over the other. The Foam Chemist should be supported
by management in trying various designs.
The Bull Cock Theory:
Bull Cock is not a vulgarity. The word Bull meaning large and the word Cock meaning faucet or valve. Therefore,
Bull Cock is a large valve which can adjust the restriction in the outlet of the mixhead and thereby adjust the
mixing pressure.
The Bull Cock is unnecessary. the same valve effect may be accomplished with a uniform diameter shaft. Above
this bulge in shaft diameter is the perfect place for the centrifugal accumulation of “air.”
The Bull Cock also conflicts with stator pins in assembly and disassembly of agitator shaft and barrel.

Page 17
 Seal Lube tank containing Back Pressure Regulator
Mesamol, mineral oil or polyether
or low viscosity polyester.
Heat Exchanger Required
Level must be continuously
to remove heat
monitored during foaming.
from seal lube circuit

Normally open
2-way ball valve
is shut on dispense

Figure 13: Drive Shaft Seal Lube

Drive Shaft Seal & Lubrication:
Figure #13. This system allows for up to 300 psi mixing pressure. Higher pressures are available with one or two
more sealing stages.

Page 18
 Figure 14: Closeup: Correct Shaft Seal Arrangement
Correct seal arrangement. Various tools are available for seal removal, installation and bearing changes.

Page 19
Part 2: Manifold and Piping Design
Cavitation and Air Hole Problems:
Air and other gasses dissolved and entrained in the chemicals and additives that blend to make polyurethane foam
have a profound effect on that foam. These gasses affect the pore size and pore size uniformity, appearance and
performance can be adversely affected with large holes and streaking related to tightness or openness of the cell
structure.
The Pinhole or Air Hole Question:
I have occasionally been called and asked for help in solving the “pinhole” or air hole problem. I don’t know if I
ever solved it. Usually, when I see a pinhole problem, there is a long history of bad piping practices,
misunderstood engineering, bad workmanship on installations, poor understanding of chemistry and physics, etc.
Most foam machines, piping and tanks included, in America at this time are decades old. As businesses changed,
customers demanded new and different things, piping and pumps were augmented, rearranged, modified with by-
passes, temporary crossovers, etc. all making these piping systems very complicated, unnecessarily complicated.
Frequently these changes have caused problems. Foam chemists have been creative in correcting and
compensating, using chemistry and foam machine parameters, to counteract errors in pumping, heat transfer and
piping.
I believe there is a logical explanation for problems. Foam making is not, as Ralph told me in 1976, a “Black
Art” which just a chosen few can master. I am not a cognoscente and this knowledge is not esoterica. "When
you have eliminated the impossible, whatever remains, however improbable, must be the truth?"5
Most of the problems I have encountered in flexible foam manufacturing are foundational in nature. That is;
equipment founded on lack of knowledge, incomplete engineering analysis, respect for incorrect tradition and
ignoring tenured employees and peers is largely responsible for much of the failure and off spec production.
Cavitation:
What is cavitation and what might it have to do with pinholes? “cav·i·ta·tion ˌka-və-ˈtā-shən : the formation of
partial vacuums in a liquid by a swiftly moving solid body (such as a propeller) or by high-intensity sound waves,
also: the pitting and wearing away of solid surfaces (as of metal or concrete) as a result of the collapse of these
vacuums in surrounding liquid”6
Cavitation occurs when there is a drop in pressure in a liquid. That drop in pressure is caused by shear. In that
pressure drop all the fluid in a very small area is drawn away in the direction of the lowering pressure, leaving
nothing behind. The size and duration of that nothing depends on temperature, viscosity, and pressure around that
nothing. A cavitation bubble is not an air bubble7.
Cavitation occurrence is directly proportional to the speed of the shearing surface and inversely proportional to
the pressure of the liquid. Cavitation occurrence is also directly proportional to viscosity.

5 The Complete Sherlock Holmes and The Complete Tales of Terror and Mystery by Sir Arthur Conan Doyle
6 Merriam-Webster Dictionary
7 Examine the propellers on a submarine. It is in the best interest of the crew, that their submarine be as quiet as possible. In the Navy, propellers are called screws.

When a submarine dives and progresses deeper and deeper, the water pressure exerted on every outside surface of that submarine increases until the downward motion
is stopped and the sub cruises at a set depth. The screws are turning to propel the sub forward and the water must pass over the surface of the screws both on the front
and back of that screw. The leading edges of the screw blades divides the water and that water slides over the screw surfaces and rejoins on the trailing edge of each
blade. Because of the rotation of the screws and cant of the blades, the forward side of the screw blades have a lower pressure exerted on them than the after side of the
screw blades. This pressure differential is what actually propels the submarine in the forward direction.
Even at lower speeds. That trailing edge is somewhat blunt and for that water to flow over the surfaces and then join together at the blunt edge takes a little time after
that edge has departed. The result is a small cavity or vacuum “bubble.” These cavities only last an instant and then they collapse because the pressure around them
forces them to collapse. When they collapse it makes a tiny snap. If the captain of our sub wants to go faster, the screws mu st turn faster and on every trailing edge of
the screw blades, cavities are forming and collapsing, by the millions, all snapping in chorus as they collapse, generating an audible crackly, hiss. It has be en described
as bacon frying. The sonar technician can monitor that cavitation and he tells the captain that the screws are cavitating. Two things can be done to reduce or eliminate
the cavitation: one is slow down and the other is running deeper.
It is possible to suddenly increase the RPM of the screws to separate the entire forward surface of the screw blades from the water, forming tremendous cavitation on
that forward side. The result is that the submarine accelerates in the direction of the cavitation.
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Because the pressure inside a cavitation bubble is so low, some of the liquid around that bubble evaporates and
fills the bubble with vapors. These vapors cannot sustain the bubble as it collapses on itself and the vapors
condense. This all happens in an instant of time.
Cavitation can occur in all the fluid systems on every foam machine. There are numerous shearing surfaces: the
impellers in centrifugal pumps, the gears or vanes or pistons in positive displacement pumps and flow meters, the
pins and blades on dynamic or static mixers. Radical and abrupt changes in piping geometry can also cause
cavitation.
Cavitation, itself is not really a big problem; however, it does have two side effects which cause problems on the
foam machine.
Cavitation erosion: as vacuum bubbles are formed and collapse the metal surfaces next to these bubbles
flex and are work hardened and eventually break away and flake off.
Dissolved gas generation: as vacuum bubbles are formed, dissolved gasses (Nitrogen, Air) come out of
solution and fill the cavities which now cannot collapse completely. Over time these bubbles coalesce
forming larger bubbles.
On every foam machine, all chemicals, whether stored in tanks drums, or totes have dissolved gasses in them.
The gas is typically Nitrogen, it is also air. Therefore, the goal is to give the gasses the least number of
opportunities to come out of solution and more importantly, eliminate the locations where they can pool into large
bubbles. Remember that air bubbles want to go up. A foam machine can process small amounts of air bubbles
with little trouble. The challenge is to keep fluids moving through each piping system without the opportunity for
entrained bubbles to pool and coalesce. If the piping geometry has recesses and hiding places of coalescence, a
bubble will eventually grow large enough to break away from its hiding place and get into that mixhead as one
large bubble. This is the cause of air holes and striations of varying pore size.
What can be done to avoid or minimize cavitation and minimize the accumulation of air bubbles?
Provide correct and sufficient pump suction pressures and sufficient suction pipe diameter. Suction piping
should be as short in length as possible. Long suction runs in polyol systems are frequently under a very
low pressure, which generates bubbles by drawing the dissolved gasses out of solution. Good piping
practice will locate a feed (supply/charge) pump adjacent to the storage tank. This feed pump will keep
positive pressure on the suction side of the metering pump.
Choose correct pipe diameters on the discharge side of supply and metering pumps.
Do not oversize piping diameter on the discharge side of pumps. If you are concerned about pressure drop,
design the pump, motor and piping for a higher pressure rather than construct with larger diameter pipe.
Minimize the number and abruptness of diameter changes. For example: in a threaded pipe system, every
connection is an abrupt diameter change. Welded systems and tubing systems such as Swagelok ® are
intrinsically smooth and continuous internally.
Minimize the number and sizes of elevation changes. In proper piping practices, an exception to the
minimize elevation change rule is applied when that piping changes direction. That is a right or left turn
should also be an elevation change. This is done so that pipe running east and west, being on a different
elevation does not interfere with pipe running north and south. With this method new piping can be added
to existing runs without difficulty. If this is not done, piping becomes confused and random creating the
need for many additional elevation changes.
Minimize the length of pipe runs.

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Examples of Piping Design Errors:
A Chemist/Foam Machine Superintendent asked to have an audit of the foam machine. Being a good friend, this
Chemist confided that for the short time of being foam superintendent, “I have made more scrap here, than in all
my previous jobs combined.” Study of the piping system showed why, perhaps this is the perfect example of lack
of engineering experience and understanding of fluid flow and foam machine design. I will use it as the example
of how not to design foam machine piping.
This customer’s nearly new installation is a perfect example of a curious disconnect between those who
design and build foam manufacturing machines and those who operate that same foam manufacturing
machine. It is a trove of examples of bad design.
The errors pictured in the figures 15, 16, 17, 18 below are indicative of design without useful experiential
knowledge. Design without proper knowledge of Fluid Dynamics. It is not the fault of the pipe fitter for
the incorporated errors. It is also noted that the pipe fitting and welding workmanship at this location is
excellent.

Figure 15: Polyol Manifold Too Large, Downhill Flow, Air Traps

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Four inch & Five inch ∅ pipe polyol manifold, design errors:
Very low average velocity (4"∅) ≈ 8.4in/sec, (5"∅) ≈ 5.4"/sec (both calculated at 100Kg/min throughput).
Injection pipes entering vertically down creating air traps.
Injection points spread widely apart causing unnecessary length of manifold.
Silver pipe is 4"∅ (x74" long), black pipe is 5"∅ (x65" long) w/ three Butterfly Valves spaced as isolation valves
in an attempt to control design error of the oversize manifold volume which is 10 gallons (36 liters).
Approximately 5° downward flow of polyol compounds with low velocity to create a difficult air trap problem.

Figure 16: Showing Air Traps and Butterfly Valves

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 Figure 17:Detail of Polyol Manifold Too Large for Small Stream Injection
There is no small stream manifold on this particular foam machine, there is only a continuation of the outsize
polyol manifold with small stream ports on top and bottom. Port spacing is 2” and 10” along the 4” diameter pipe.

Figure 18: Detail of Polyol Manifold Flowing into Mix Chamber

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Improved Manifold Geometry:
The Modular Polyol Manifold:

Figure 19: The Modular Polyol Manifold

Modular configuration, using Tri-Clamp union connections can easily be adapted to foam machine needs. Inlet
flanges can accommodate NPT, ANSI flange, etc.

Figure 20: Plan View of Low Volume, Modular Manifold

1.87” inside diameter manifold more than quadruples velocity as compared to 4” diameter and 6.25X velocity in
the 5” diameter pipe with close proximity of injection points also reduces volume and therefore time lapsed in the
manifold.

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 Figure 21: Modular Manifold Installed
2” ID modular polyol manifold is designed such that 3-way valves (polyol streams) may be added easily

Figure 22: Modular Manifold Components

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 Figure 23: Worcester diverter valves bolted directly to Modular Manifold minimizes dead space volume.

Figure 24: 30 Port Small Stream Manifold, 3” OD x 1½” ID Heavy Wall Tubing

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 45.509 57.372

33.500

Existing mixhead centerline

Figure 25: Proposed Fix Using Elements as Discussed

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Part 3: The TDI Manifold
TD65 Air Op
3-way valve TD80 Air Op
Multiport TDI
3-way valve
manifold

TD65 de-gas
or gassed Air Op
TD80 de-gas
3-way valve
or gassed Air Op
3-way valve

XRT563 injector

XRT563

USA
XXX
O-Ring EPDM
#018

SCV5 1 2"Ø Safety Cutoff Valve

with limit switch package

Figure 26: TDI Manifold Example

The Utilitarian Value of the TDI Manifold.
In all my experience with foam machines, TDI systems are by far the most dangerous to the health and wellbeing
of employees with the highest potential of monetary liability in health care and environmental damage and
subsequent cleanup costs.
The injection nozzle is perhaps the point in any TDI system most susceptible to problems, whether it be
overpressure, inconsistent pressure, non-uniform spray pattern, etc. This susceptibility is minimized with
fastidious preventive maintenance and care. The TDI injector cannot be expected to perform consistently if it is
not well maintained, kept clean and properly assembled. Typically the problem with TDI injectors is maintenance
attempted by uninstructed personnel.
The injection point of TDI into the foam mix chamber is that point which many employees interact daily,
including exposure to liquid and vapors of TDI.

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If a foam machine has a complicated TDI conditioning system, including degassed and gas enriched TDI and
various ratios of 2-4 and 2-6 isomers, it is greatly simplified by incorporating the TDI manifold pictured in Figure
#26 above.
The TDI manifold has many advantages:
Reduces the number of injection points to one. With one injection nozzle all the throughputs are combined
allowing that single injection nozzle to operate at approximately the same throughput and pressure, day
after day.
Pressure adjustment is reduced to one injector.
Ratio change will not cause a pressure fluctuation.
Maintenance is simplified because there is only one injection nozzle to care for.
In the case of the foam machine which has a conventional and a CO2 mix chamber, it is a very simple
matter to move that one injector from one mix chamber to the other.

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