Sandwich Foam Production Line

COLD STORAGE PANEL

Given their excellent range of properties, sandwich panels with a polyurethane core provide an alternative to traditional construction methods - not only in economic, but above all in ecological terms. Our production lines are used worldwide for the continuous manufacture of insulating panels. But in many applications, the discontinuous production process offers decisive advantages and important unique features. For instance, when using facing material with specific properties or incorporating special mechanical fixings within the panel. Discontinuous panel manufacture also makes sense for lower production volumes or when extraordinary dimensions are required. Cold storages and cooling trailers are an important field of application, as is the construction sector, both private and commercial. Users all over the world rely on flexible.

MACHINE FEATURES

production systems for the discontinuous manufacture of sandwich elements offer an extremely wide range of dimensions, facings and foam systems. The combination of high quality and reliable hydraulic presses for nearly all applications together with established high and low pressure metering systems guarantees efficient manufacture of products with an excellent range of properties.

Metering machine (wet part)

The plant concept uses a tried and tested metering system to supply the reactive PU composite using high or low-pressure mixing, depending on the application. The reliable plants feature first-class metering pumps, a modern plant automation and ensure optimal mixing of the reactive components at all times. Further advantages are the work tanks which are available in different sizes for various applications, solutions for using several mix heads at once and for using pentane, as well as all safety devices. Due to the combination of peripheral equipment or special mix heads, the wet part of the PANELFOAMER can be individually adapted to suit many different applications. This includes the planning and implementation of tank farm systems with all safety equipment.

Presses (Intro)

The presses' upper and lower plates are constructed from heavy duty steel. To ensure that the panels are flat and parallel, the plates are fitted with a precision-made, heated metal layer, which ensures, via integrated hot water pipes, that the plate temperature remains in the ideal range under all operating conditions. This achieves an improved distribution of the reactive composite within the panel as well as reduced curing times and optimum insulating properties. Clamping cylinders provide the necessary "pressure". In order to create a stroke which is as close to parallel as possible, the presses are equipped with a tooth rack drive system, depending on the application. Despite the high pressure generated during the foaming process, the entire plant is extremely torsion resistant. This is due to the robust structure consisting of rectangular upright support frames fixed to longitudinal foundation beams, forming an effective structural frame combining high strength and rigidity with relatively low weight. Furthermore, the press design ensures versatile connectivity with the mixhead, which can move, for example, along a traversing rail system fixed to the main press structure. This means that even large panels can be filled with foam easily. The portfolio includes special designs for using with rigid or flexible facings made of different materials (e.g. steel, aluminium or fiberboard) and in a variety of applications.

Book opening presses

Book opening presses are used when open pouring is necessary. This is usually the case when big panels with trapezoidal shapes or undercuts (e.g. roof panels) are made. Here the mixhead travels along the whole length of the press using a linear system. The facings are applied manually.

Shuttle-type press

The stroke movement in shuttle-type presses is particularly good for the production of large volumes because the process is so efficient. Loading and unloading takes place in a shuttle system that is largely automated. Traversing plates with frequency-controlled acceleration supported by wheel assemblies are used here. In this way, component parts can be prepared outside the press while a second set is curing inside. This system ensures that the press is used to maximum capacity at all times. Apart from improving user-friendliness, this technology also increases production yield significantly. Hennecke-OMS offers its customers 1+1 and 2+2 shuttle systems.

Multi-daylight press

In a multi-daylight press, the pre-assembled component parts are inserted into the press sideways. Each level is ergonomically loaded from the outside, either manually or automatically using a scissor lift table. Once all the levels have been loaded, this triggers the press movement which clamps the component parts together using distance plates. This system is ideal for small and medium-sized production batches.

Applications

Making panels for cold storages and cooling trailers

One of the principal uses for discontinuously produced sandwich panels is in the construction of cold storages. The wide range of applications is demonstrated by the large number of closed cool chains for food products and all other goods that need to be stored at low temperatures. The number of customers is growing continuously, as is the number of special applications, such as indoor facilities for skiing or ice sports. Whether they are standard or tailor-made, the requirements needed to make cold storage panels mean that discontinuous production is almost indispensable. One example is when special interlocking systems need to be incorporated into the foaming process.

The production of structural insulated panels (SIPs) and full wall timber frame construction for insulating buildings

The effective insulation of private homes is becoming increasingly important in light of the current debate on energy and the reduction of CO2 emissions. PU insulation in the form of SIPs and full wall timber frame construction gives significant advantages over the use of traditional materials such as mineral wool or cork. Furthermore, they contribute to an effective reduction in CO2 emissions and bring significant savings in heating costs compared to non-insulated designs.

The production of panels for industrial applications in the construction sector (modern methods of construction MMC)

Sandwich panels produced using the discontinuous method also provide unlimited design freedom in the industrial construction sector, even when the production volumes are manageable. And this does not stop at the visible design but is also noticeable in the special solutions for fixings that cannot be made in continuous production.

The production of panels for special applications

Special applications call for special solutions. The concept is a comprehensive customer-specific package that can be tailor-made to fit any application perfectly. In the past, for example, effective production solutions have been developed for swimming pool insulation, special floor elements with integrated heating, or ceiling linings.

Optional equipment and additional components

Hydraulic de moulding

A panel restraint system is available with hydraulic actuation. Hydraulic equipment is provided to constrain sideward pressure during the foaming process. Tailored to suit the respective panel edge detail, demoulding is made easier and thus the production speed increases.

Lifters and booms

When handling facings and finished panels we also rely on different tried-and-tested systems. These measures improve the production cycle but above all they guarantee ergonomic production with a minimum of personnel.

De stacking

When big production volumes are in play, it makes sense to use automatic destacking equipment. By using vacuum suction cups, anti-magnetic facings can be handled easily. The surface of the panel is also well protected. If necessary, the destacking equipment can be programmed.

Cold Storage Panel

Rigid polyurethane foam has the lowest thermal conductivity of all insulating materials and is therefore used in the form of metal composite elements in industrial and cold store construction, as well as in cooling chambers for supermarkets and in thermal assemblies for trucks. With its highly developed, continuously or discontinuously operating sandwich panel lines, We have played a decisive role in this success story right from the start. The plant is designed for the continuous production of top-quality sandwich panels with different facings, panel thicknesses and profiles and the option of a core structure made of polyurethane or mineral wool. It is also has a highly-specialized provider of high-performance trapezoidal sheet roll forming systems, which can be seamlessly incorporated into the existing plant concept for the continuous sandwich panel lines. In the continuous production of sandwich elements with metal facing, that can offer its customers convincing all-round solutions from a single source.

Profiling

The entry section contains the equipment for handling the coil and processing the metal facings. This includes unwinding and feeding the steel coils into the plant, preparing the strips by trimming and connecting them, as well as the profiling of the lower and upper metal facings. The surface and edge profiling gives the sandwich composite elements a defined shape and joins them securely together.

The profiling section usually comprises the following parts:

• Facing infeed

• Lining

Mixing and metering

We offers the entire equipment for the metering, storage, transport, and monitoring of raw materials and additives The polyurethane metering machines are responsible for the homogenous mixing of the reactive components polyol and isocyanate, as well as various additives (e.g. catalysts, blowing agents, curing agents, flame retardants). sandwich panel production lines are based on a well-planned arrangement of the individual units and top-quality components. This guarantees the user a uniform cell structure and an efficient raw material yield.

The raw material dispensing equipment, or wet part, usually comprises the following:

• Metering units

• Dynamic premixing station and gas loading system:

• Mass flow meter

• Temperature control unit and cooler

• Tank farm

COLD STORAGE PANEL PANEL PRODUCTION LINE

CONTINUOUS SANDWICH PANEL LINE

TURNKEY CONTINUOUS PU SANDWICH PANEL PRODUCTION LINE

Continuous sandwich panel line is a complete automated plant designed to efficiently respond to high productivity standards and allow the production of panels with different thicknesses, facings, profiles and cores.

A complete sandwich panel line with high productivity rates and flexibility

Continuous line is an automatic plant for sandwich panels production in continuous mode. Different specific-use sections are pre-engineered and integrated one after the other to work in continuous and ensure constant level of production. The seamless flow of materials and operations through these sections not only optimizes efficiency but also plays a pivotal role in upholding the quality and consistency of the final sandwich panels. Indeed, the plant allows mass production of panels having the same aesthetics features, structural integrity and quality standards. Also, every line can be specifically designed by according end-product’s specifications required by the customer including different thicknesses, facings, profiles and cores.

Standard configuration of continuous sandwich panel line

In the process of continuous sandwich panel production, a well-orchestrated series of specialized sections is arranged, forming a cohesive and interconnected line. Each section is designed to execute a specific function, crucial to the overall manufacturing process, ensuring that the production line keeps a constant and uninterrupted level of output. Here follow the main sections of the plant.

Roll forming section

An uncoiling unit is placed at the beginning of the continuous sandwich panel line to hold and drive the steel coil feeding the roll forming machine. Thanks to an automatic connecting system, it’s possible to connect two coils without stopping the line. The roll forming section consists of both upper and lower forming group whose main function is to prepare both metal facings of sandwich panels according to the end product’s characteristics. Individually controlled top and bottom steel pre-heaters heat the steel to the correct temperature prior to the application of the polyurethane. Also, the plant can include a specific unit to apply corona treatment on surface sheets. This allows to increase wettability and eliminate static electricity, therefore ensuring better adhesion of foam and improve the quality of the end product.

Foaming and double belt section

Foaming section is a key stage in sandwich panel production process. More precisely, multi component dosing unit is at the heart of the continuous sandwich panel line. Thanks to an extensive experience in the field, our company can provide highly customizable solutions to produce premium quality panels using isocyanate, polyol (PIR and PUR), pentane, catalysts and additives.

The very next section is the double belt having a relevant role in determining both panel flatness and polymerization process success. can supply modular double belt conveyors with different lengths according to specific production needs. Their premium design is the result of years of manufacturing experience and feedback from operating units.

Rockwool section (option)

According to final application of sandwich panels, customers can choose either polyurethane or mineral wool core. Rockwool is a completely natural product which combines great properties of strength, fire protection, incombustibility, thermal insulation and soundproofing. However, as it is not a self-adhesive material, the right equipment is required for mineral wool mattress loading, cutting, handling and gluing. To this end, the continuous line designed by can be adjusted and integrated with a specific section dedicated to rock wool processing:

· handling, cutting and orientation of lamellas

· queuing of oriented lamellas and milling of lateral joints

· preparation, orientation and insertion in line of trapezoidal profiles

· dust suction

Cutting section

After leaving the double belt conveyor, sandwich panels proceed towards the cutting section where finished panels are cut to the desired length. The cutting machine of sandwich panel machine is composed of an automatic panel cutting system with band saw, laminator out-feed conveyor and cross cut with band saw.

Handling section

Before staking and packing, a conveyor with lateral translation belts receives the cut panels coming from the cross-cutting machine and push them into the cooling system. Here a set of vertical forks hold the panels in vertical position while a cooling process allows heat dissipation and prevents surface deformations determining the final quality of panels.

Finally, the continuous sandwich panel line is equipped with a handling section where the last production stages take place. First, the stacking unit is designed to stack the finished panels exiting from the cutting or cooling section. Then, the stacked panels are then wrapped thanks to the packing unit placed at the very end of the line.

CONTINUOUS PU SANDWICH PANEL PRODUCTION LINE

DISCONTINUOUS SANDWICH PANEL LINE

TURNKEY DISCONTINUOUS PU SANDWICH PANEL LINE

Discontinuous PU sandwich panel line is a turnkey plant including one high or low-pressure foaming machine and one press of any type, preferred for low production rates and customized shapes, dimensions and finishing of panels.

Features and benefits of using a discontinuous polyurethane sandwich panel line

There are applications where discontinuous production of PU sandwich panels can be the most fitting choice rather than the continuous mode. First, this process is preferred to incorporate facing materials with specific properties or special mechanical fixings within the panel. Secondly, it is recommended for applications where lower production rates, particular shapes or variable panel dimensions or layouts are required.

Discontinuous PU sandwich panel plant/line is specifically designed and manufactured for such applications. The brand-engineered high and low-pressure dosing machines can be matched with different types of presses for the production of panels in discontinuous mode. Our company can support each single customer in finding the right match between dosing machine and press, studying and developing the best solution for its production needs.

High and low-pressure foaming machines

discontinuous sandwich panel line includes reliable polyurethane dosing machines for extremely precise and quality production of polyurethane foam. Depending on the application, high or low-pressure technology can be used for the production of rigid and flexible foam. As per standard configuration of each machine, pumps, mixing heads, tank modules, control and safety equipment are engineered by Ekosystem to ensure optimal results. However, high customization is possible according to production needs and end product’s specification.

Type of press for our discontinuous PU sandwich panel machine

Good sandwich panel production requires the help of a press which is able to provide the right clamping force to foam, plates thermoregulation and productivity optimization. discontinuous PU sandwich panel machine can integrate different type of presses whose selection depends on production needs, required panels specifications and efficiency goals. The first basic difference lies among manual and automatic presses. Respectively, they can be preferred for easy, cost-effective smaller-scale production or efficient, higher production rates. For large-scale production of and medium-sized panels above all small, there are also multi-daylight presses where multiple panels can be processed simultaneously, increasing overall capacity. Instead, angular press and presses for corner panels are designed to mold panels with custom-shaped panels ensuring precise and consistent results.

Specially Designed for Polyurethane Processing and Versatile in Use

With the pump axial piston pump that has been developed exclusively for polyurethane applications. Development focused on creating a precise, highly efficient and future-fit metering line that offers our customers real value when processing polyurethane. It is a completely new pump generation and is manufactured exclusively at our Sankt Augustin site.

OPTIMIZED DESIGN

It offers a significantly optimized pump housing, enabling maximum bearing flushing thanks to a newly developed bearing seat. This ensures efficient heat dissipation and prevents a rise in the reactive media temperature. This highly effective self-cooling even works at high ambient temperatures and offers a significant advantage compared to other pumps on the market. The selection of materials and their surface protection were specially designed for use in polyurethane foaming systems.

The pump housing has a compressive strength of up to 16 bar. This ensures more efficient heat dissipation from the high-pressure pump even in the event of high pre-pressures.

The pump design improves suction. This is a particularly noticeable advantage when working with high-viscosity components, so that the HX pump can be supplied with lower pre-pressures depending on the area of use. It may mean that pre-pumps are not required

TURNKEY DISCONTINUOUS PU SANDWICH PANEL LINE