HIGHLINE MK2 TI SERIES: Specialist for technical insulation

Hennecke is continuously developing its portfolio as part of its NEXT-GEN platform strategy. With the HIGHLINE MK2 TI SERIES, the company is now presenting another new high-pressure metering machine for rigid foam processing, which, as a cost-efficient all-rounder, makes no compromises in terms of mixing quality, raw material efficiency and digitalization. It succeeds the highly successful TOPLINE HK TI machine type and marks an important milestone in Hennecke‘s FOCUS2030 strategy. The company consistently pursues its Local-for-Local approach, offering the machine worldwide with identical performance data while tailoring its technical design to meet specific market requirements.

With the TI SERIES, Hennecke presents a machine line for the partially and fully automated production of energy-efficient PUR rigid foam insulation, for example in the refrigeration cabinet industry. A particular focus is on the safe handling of various blowing agent systems, from water to HFO and pentane. This means that the machine is optionally available with all the necessary equipment features for pentane processing, which can be fully integrated into Hennecke’s proven PPT safety concept (Pentane Process Technology).

The new metering machine is based on the proven HIGHLINE MK2 platform with its advanced FOAMATIC control system, innovative common parts concept and integrated Blue Intelligence technology. This technological basis ensures maximum precision in metering, as well as reduced delivery times and an attractive pricing through to the use of standardized components. “This significantly improves both process and product quality, especially when using highly reactive and demanding rigid foam systems,” says Dr. Joachim Berthold, Senior Director Sales Molded Foam, Slabstock & Technical Insulation, underlining the benefits.

The HIGHLINE MK2 TI SERIES boasts several groundbreaking technical features that are not available in the standard configuration of the HIGHLINE MK2 series. For example, the TI SERIES offers significantly larger day tanks with a capacity of 500 liters. The double-walled tanks are equipped with liquid temperature control, refill control and agitator as standard. “TI SERIES machines have a common machine frame for day tanks and pumps. This makes the system very compact and allows it to be installed on site with significantly shorter assembly times,” says Dr. Berthold, explaining the proven Hennecke one-frame design. The machine is also available with two mixheads. In this configuration, the machine is supplied with appropriate switching devices for sequential foaming, for example for use on two mixhead manipulators or on two production lines.

Despite the compact footprint of just 8.7 square meters, the machine offers very good access to the main components for maintenance. In addition, flexible and space-saving integration into existing production lines is possible, particularly when positioned on a platform. The machine can be supplied with fully customized piping and tubing for easy integration into existing plant networks. Predefined outlets make it easy to connect the required piping.

To maximize precision and switching accuracy, especially with long pipe and hose lines, the mixhead control valves are removed from the machine and positioned closer to the mixhead. This ensures maximum metering accuracy at all times.

The hydraulics have been upgraded from 11 to 15 kW for the high shot frequencies in refrigerated appliances production. “This powerful equipment is specially dimensioned for the intensive cycle rates of industrial production,” explains Dr. Berthold. The hydraulics use the quietest pumps on the market and an additional oil cooler reliably prevents overheating during continuous operation.

A particularly powerful temperature control system ensures constant raw material temperatures even in extreme production environments. An optional air conditioning unit for the control cabinet is also available for operation at extremely high ambient temperatures. For the safe processing of pentane, Hennecke relies on targeted and highly efficient local extraction instead of a large enclosure. This means that access to the machine is not impaired and maintenance is made considerably easier.

A special variant of the new HIGHLINE MK2 TI SERIES is equipped with four metering pumps and two mixheads. This allows both mixheads to be operated simultaneously. This is particularly important in the production of refrigerator doors with fast and particularly energy-efficient foaming systems. For example, two doors can be filled at the same time. This configuration increases production efficiency and ensures maximum productivity, particularly in demanding production systems. “With this solution, we offer manufacturers maximum process reliability when processing modern high-performance foam systems,” emphasizes Dr. Berthold. This special variant of the TI SERIES is also characterized by a very compact size thanks to the previously mentioned one-frame design.

The TI SERIES exemplifies Hennecke’s Local-for-Local approach within the FOCUS2030 strategy. The machine is offered worldwide with identical performance data, but its technical design is specifically adapted to the respective regional market requirements. “This strategic flexibility enables us to optimally serve international customers and at the same time respond to the specific needs of dynamically growing markets such as Asia,” says Jorge Zazueta, Director Global Sales Appliances, explaining the approach.

A version already available for the APAC region, produced by the Hennecke Center of Excellence China, illustrates this strategic flexibility. This version is specially designed for Asian markets and uses locally available quality components that meet the respective standards and requirements. The performance data and product quality remain identical for all machines in the HIGHLINE MK2 TI SERIES. This regional customization enables customers to receive a cost-optimized solution with very short delivery times that is precisely tailored to their local needs.

All NEXT-GEN metering machines from Hennecke are equipped with the intuitive FOAMATIC control system including a practical “three-click philosophy”. The high-resolution 12-inch premium HMI enables maximum control and quick access to all relevant functions – efficient and user-friendly at all times and available in many languages. In addition, FOAMATIC offers optional IoT connectivity with access to extensive machine data and analysis tools for boosting production efficiency as well as predictive maintenance.

Hennecke’s Blue Intelligence technology – a comprehensive package of measures to increase energy efficiency – is also integrated as standard. Intelligent functions such as start-stop logic, optimized pump lead times and precise temperature control management can reduce the machine’s energy consumption depending on the respective operating conditions and lower operating costs.

The modular design of the MK2 platform makes it possible to cover the entire spectrum, from cost-effective standard solutions to maximally optimized high-performance requirements for complex production applications. The modular system and the common parts concept ensure significantly reduced delivery times. “The modular structure also enables attractive pricing along with a high degree of flexibility for our customers,” says Patrick Brüninghaus, Director Product Management, summarizing the advantages of the platform strategy.