Flexible Facing (PU, PIR, Phenolic, Board Panel)

1. Uncoiler System

• Uncoiler is no drive type, and is installed two each at the upper part and the lower part separately.

• Consists of : Uncoiler, Auto tension unit, Auto centering unit

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2. Pre Heating

This unit is used for preheating the upper and lower steel sheet to a moderate temperature after roll forming process. As polyurethane reacts chemically under moderate heat, the heating process for the steel sheet activates PUR and makes the adhesive strength between the steel sheet and PU foam stronger.

3. PU Metering Machine

• One of the most important part of the board panel line is the PU metering machine.Panel quality depends on the performance PU machine.The PU metering machine consists of pumps for:

  • Iso
  • Polyol
  • Catalyst (1/2/3)
  • Blowing agent (Pentane)

  Depending on the number of catalysts used, the components of PU machine are determined. 4-6 component machines are mostly used.

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4 & 5. Foaming Portal and PU Injection

• PU material is discharged from the outlet pipe of the mixing head onto the lower facing layer while moving crosswise along the Foaming Portal (Coating Gantry).

• The mixing head is actuated by means of an A.C servo motor and its toothed belt enables a free programmable oscillating movement across the total panel width.

• There is no noise from the movement of the Foaming Portal.

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6. Double Conveyor Belt

• PU foam component mixture applied to the lower facing layer is conveyed in a synchronization motion with the upper facing layer along the double belt for curing.
• This unit is a crucial part and plays a core role in ensuring the highest standards of sandwich panels.
• This unit principally consists of driving motion, upper and lower slats, a hydraulic cylinder or screw motos to contain the rising pressure and a side guide and dice block to prevent PUR foam from leaking out of the sides.

7. Cutting (Disk Saw)

• The cutting speed is precisely synchronized with the board conveying speed.
• This cutting unit can be operated both manually and automaticlly.
• The gantry is set at the rear and the saw unit is positioned on the right-hand side as viewed from direction of production.

8. Cooling

During the production of PIR and PU boards, depending on the thickness of panels heat would be generated due to chemical reactions. In the case of PIR and thicker PU boards, products must be cooled down to room temperature in order to avoid defects in the final products. Cooling device is designed in a way that takes the boards after cutting and delays their arrival for stacking and packing. The speed of cooling could be adjusted as required.

9. Stacker (Lift Type)

• This process is designed to stack finished boards efficiently at the production speed.

• It is very important that the stacking speed should not be slower than board production speed.

• It is possible to stack boards by an automatic or manual operation.

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10. Packing (PVC Wrapping)

This process is designed to pack boards bondless by use of PVC stretch wraps before final delivery.

11. Aluminum Foil Embossing Machine

This machine is specially designed for embossing aluminum foils with the thickness of lower than 0.1mm. The use of aluminum foils or other materials with thickness exceeding 0.2mm is not recommended.

PU Board