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. PANELMASTER 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 PANELFOAMER systems concepts by Hennecke-OMS.
PANELFOAMER 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 Hennecke-OMS metering systems guarantees efficient manufacture of products with an excellent range of properties.
Metering machine (wet part)
The PANELFOAMER 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 mixheads at once and for using pentane, as well as all safety devices. Due to the combination of peripheral equipment or special mixheads, 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.
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.
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.
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.
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 PANELFOAMER 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
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.
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.