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INNOVATION IN INSULATION
Continuous production lines for sandwich panels
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KRAUSSMAFFEI
Supplying complete, turnkey systemsfor the production of
sandwich elements
Sandwich elements have become essential in theconstruction
industry. They are used alongsidetraditional building materials
such as wood, steeland concrete and have become the rst
choicematerial for the realization of various buildingssuch as
production halls, airports, exhibitionhalls, cold rooms, plants,
agricultural buildingsand many others. The reasons for this
trendare to be found in their excellent proper ties asinsulating
elements. Architects select thesemultilayer panels for many
reasons, including theirdesign potential and aesthetics, and their
staticand acoustic properties. The choice of materials forthe core
and outer layers is determined bythe specications for the sandwich
elements.
Design and cost considerations
Sandwich panels are easy and fast to install, they canbe
produced rapidly and on demand in therequired quantity and length,
and they can be easilytransported to wherever they are needed.
All in all, sandwich panels are a lower cost solutioncompared to
traditional building materials. Thecurrent trend is to use sandwich
panels to constructthe complete outer shell of buildings.
Architectsspecializing in the design of private housing
havepresented successful solutions ranging fromluxury homes to
affordable housing for under-privileged people.
Continuous and discontinuous
KraussMaffei provides the expertise to engineeroptimized systems
for manufacturing sandwichelements. Our products cover all the
options
from presses where the elements are produced oneby one to
complete production plants, including
double belt presses, designed for mass productionof sandwich
elements.
Arena-administration building, Libourne + Marigot Ofce
M.O. Btiment, France
ROTEB waste incineration
plant, Rotterdam, Netherlands
West facade of the Pride Park
Stadium, Derby, UK
Continuous production lines
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CONTINUOUS PRODUCTION LINES
Engineered to perfection for outstandingquality in sandwich
elements
Production systems engineered by KraussMaffeimeet all the
criteria for high-tech productionsystems for insulating panels.
Whatever the targetuse for the sandwich panels industrial
buildings,cold rooms, prefabricated houses, or wall and
roofinsulation our production systems ensurehigh-performance
process technology. The result isexcellent product quality.
KraussMaffei design Continuous production linesfor high-volume
production of insulating panels.A Continuous production line is a
turnkey solutionfor continuous production of insulating panels.
Continuous production lines integrates
1 feeding and forming the facings2 roll-forming the facings3
feeding equipment for the mineral wool or
other core materials4 metering and mixing the PUR/ PIR
components5 application of foam or glue6 the lamination unit or
double belt press for
calibrating and curing the panels7 cutting the elements to
length
8 cooling, stacking and wrapping the elements
> Production speed: up to m/min> Panel width: to mm
Continuous production lines
KraussMaffei double-belt press
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RIMSTAR
Mixing and metering machines for PUR/PIRprocessing and
application
KraussMaffeis RimStar family of mixing andmetering machines are
available in versions toprocess from to components. PUR gluesystems
typically use components with an outputof g/sec. PUR/PIR systems
for sandwichelements use at least components, including a
blowing agent such as pentane; their output isseveral
kg/min.
The application of the PUR glue system or the lay-down of the
PUR/PIR foam application is the keytechnology for a sandwich
element production plant.
KraussMaffei supplies a full range of different mixingheads each
engineered to meet specic requirements.For the application of PUR
glue, KraussMaffeideveloped a Jet mixing head which applies glue
withor without llers in a uniform layer on the facings.A rate of,
for example, g/m without oversprayhas been achieved. The PUR/PIR
foam is laid downusing mixing heads designed specically for
sand-wich element production. For sandwich panels withrigid
facings, foam application can be optimized byadding a special tube
(poker) equipped with smallfoam outlets which ensure perfect distr
ibution
of the foam on the lower facing. For insulationboards with
exible facings produced at high speed, L-design mixing heads
positioned one beside
the other supply foam in the required quantity andquality.
Turnkey production lines
KraussMaffei supplies complete lines, including theuncoiling
units, for producing sandwich elementswith exible and rigid facing
layers, or the feed unitsfor panels or mineral wool. For metal
facingsKraussMaffei supplies state-of-the-art roll
formingequipment. After calibration and curing, a completeline will
include saws, cooling conveyors, stackingand wrapping units. These
downstream units are
chosen and integrated to match each customersspecial production
requirements.
Continuous production lines
RimStar
Handling equipment
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STRUCTURED SANDWICH PANELS
Versatile and optimized for each application
Depending on the required properties and theapplications, a wide
range of composite structureshas been developed to create sandwich
elementsfor different needs. The characteristics of the coreand
outer materials determine the properties ofthe elements. The core
material of sandwich elementscan be, for example, PUR foam, PIR
foam, mineralwool, paper honeycomb, glassber reinforcedPUR, PUR
mixed with particles of other materials,XPS, EPS, or combinations
of different materialsas composite structures. The material used
for theouter layers can be divided into two categories:
Rigid layers Metal sheet such as steel, stainless steel,
copper,
aluminum Boards such as OSB, MDF, gypsum and boards
made of various ber-reinforced materials
Flexible layers Paper, aluminum, PVC and other plastics,
glassber reinforced lms.
Examples of s andwich elements:
Sandwich panelLayers: Painted steel sheet for strength anda
high-quality surfaceCore: PUR/ PIR foam or mineral wool to
provideinsulation and reduce weight
Insulation boardLayers: Aluminum foil to provide a vapor
barrierCore: PUR/PIR foam to provide insulation andreduce
weight
Construction panelLayers: High Pressure Laminates (HPL) to
providea high-quality surfaceCore: PUR foam or XPS to reduce
weight
Light-weight panelLayers: Plywood to provide strengthCore: Paper
honeycomb to reduce weight
Multi-layer wood panelSeveral layers: Thin OSB or plywood
boardsto provide strengthBonding material: Glassber-reinforced PUR
glueto provide strength
Walls for pre-fabricated house
Layers: OSB to provide strengthCore: PUR foam to provide
Insulation and lightweight
Faade panelLayers: Painted aluminum sheets to provide
ahigh-quality surface and environmental durabilityCore: Extruded
HDPE or PVC to provide strength
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KraussMaffei is a premium partnerfor the plastics and rubber
processingindustries worldwide.
Production systems engineered by KraussMaffei meet all the
criteria for high-tech production systems for insulating
panels.Production systems engineered by KraussMaffei meet all the
criteria for high-tech production systems for insulating
panels.
Whatever the target use for the sandwich panels industrial
buildings, cold rooms, prefabricated houses, or wall and
roofWhatever the target use for the sandwich panels industrial
buildings, cold rooms, prefabricated houses, or wall and roof
insulation our production systems ensure high-performance
process technology. The result is excellent product
quality.insulation our production systems ensure high-performance
process technology. The result is excellent product quality.
Service, support and spare parts when you need them, where you
need themService, support and spare parts when you need them, where
you need them
Rely on us for a fast and competent response to all your service
needs anywhere in the world. From troubleshooting and trainingRely
on us for a fast and competent response to all your service needs
anywhere in the world. From troubleshooting and training
to spares or repairs were on the job.to spares or repairs were
on the job.
Benefits for your businessBenefits for your business
The systems are modular and perfectly tailored to theThe systems
are modular and perfectly tailored to theapplication and to
customer requirementsapplication and to customer requirements
KraussMaffei stands for state-of-the-art machinery,KraussMaffei
stands for state-of-the-art machinery,proven and reliable concepts
and highest product qualityproven and reliable concepts and highest
product quality
Energy consumption is low due to the efcient, proprietaryEnergy
consumption is low due to the efcient, proprietaryrouting of the
heating air through the double belt unitrouting of the heating air
through the double belt unit
Turnkey project management by KraussMaffei specialistsTurnkey
project management by KraussMaffei specialists
Competitive advantage from sandwich elements with a
high-Competitive advantage from sandwich elements with a high-value
surface due to high-precision calibrationvalue surface due to
high-precision calibration
Change of thicknesses and widths is fast, easy and
errorproofChange of thicknesses and widths is fast, easy and
errorproof
Highly automated, cost-effective productionHighly automated,
cost-effective production
KraussMaffei has designed and manufactured equipment for the
polyurethane industry for more than years now.KraussMaffei is the
technology leader in several market segments, where we are
considered to be the reference supplier.We have the experience and
know-how to support you, our customers, every step of the way from
the initial idea,through development of the optimal solution, to
commissioning, operating and servicing your system. At all
times,
you can rely on our outstanding competence in planning and
engineer ing and on our fast-response service and support.
RimStar KraussMaffei double-belt press
KraussMaffei Technologies GmbH
Krauss-Maffei-Strasse Munich
Phone + - Fax + -
www.kraussmaffei.com
