STATE OF THE ART IN EQUIPMENT FOR DISCONTINUOUS PANELS MANUFACTURING. MANNI PRESSE The dry side of polyurethane

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1 STATE OF THE ART IN EQUIPMENT FOR DISCONTINUOUS PANELS MANUFACTURING MANNI PRESSE The dry side of polyurethane Cristiano Ligabò Manni Presse

2 Manni SpA Manni company More than 35 years experience in polyurethane discontinuous plants engineering and manufacturing Presses, fixtures, handling devices fully customized Customer and final user oriented attitude for quality, safety, ergonomy and productivity

3 Discontinuous technology basic concepts - the discontinuous production is for: Higher complexity panels (with inner frames, locking system, special shapes) Ready to install panels High flexibility demand due to a wide production mix

Manni SpA Discontinuous technology basic concepts closed injection and open mould

created by the press platens and moulds to be filled with a single or multiple

Press Platens Injection head The open mould pouring In this method the PU is poured out

4 Manni SpA Discontinuous technology basic concepts closed injection and open mould pouring The closed mould injection In this kind of technology we have a closed cavity created by the press platens and moulds to be filled with a single or multiple injections. Press Platens Injection head The open mould pouring In this method the PU is poured out of the press on one of the two skins of the panel, after this the poured skin reaches the other skin inside the press to compose the finished panel Cavities to be filled Lateral frame

5 Discontinuous technology basic concepts use of pentane. The standard developed is according ATEX/94/9 EU: Press equipped with optimized ventilation ducts If necessary motorgears/encoders/vacuum pumps Ex II2G (open mould pouring) Complete grounding of the press and use of antistatic or conductive parts Sensors and limit switches with barriers Integration with wet side safety system

6 Manni SpA Discontinuous technology basic concepts use of pentane.

Manni SpA Some significant works Chile PRODUCT: refrigerated containers = floor, roof, walls, front end, doors panels FOAMING TECHNOLOGY: closed mould injection (simultaneous in two points or step by

7 Manni SpA Some significant works Chile PRODUCT: refrigerated containers = floor, roof, walls, front end, doors panels FOAMING TECHNOLOGY: closed mould injection (simultaneous in two points or step by step in multiplepoints) + tilting. Pentane: Ex presses PRESS TYPE: trolley presses, n (two trolleys in press each cycle) and n (one trolley in press each cycle) AVERAGE PRESS PLATENS DIMENSIONS: around 12X3m for bigger panels, 6x3m for integrated fronts, 3x3m for doors; min 145 tons, max 700tons total force ACCESSORIES: press body tilting, dedicated moulds and demolulding system, foaming heads handling

8 Manni SpA Some significant works Chile

Manni SpA Some significant works UK PRODUCT: prefabricated buildings = wall and roof panels FOAMING TECHNOLOGY: open mould pouring (max 18kg/second) PRESS TYPE: trolley press, 2+2 open mould pouring

9 Manni SpA Some significant works UK PRODUCT: prefabricated buildings = wall and roof panels FOAMING TECHNOLOGY: open mould pouring (max 18kg/second) PRESS TYPE: trolley press, 2+2 open mould pouring press PRESS PLATENS DIMENSIONS: 20.2x4.4m (max panel dimension 20x4.2m); max force 1550 tons ACCESSORIES: dedicated moulds and demoulding system, handling system for moulds, additional trolleys position for higher production flexibility,

10 Manni SpA Some significant works UK

Some significant works Germany PRODUCT: doors FOAMING TECHNOLOGY: gluing + closed mould injection PRESS TYPE: multidaylight press independent opening (10 daylights) PRESS PLATENS

11 Some significant works Germany PRODUCT: doors FOAMING TECHNOLOGY: gluing + closed mould injection PRESS TYPE: multidaylight press independent opening (10 daylights) PRESS PLATENS DIMENSIONS: 2.65X1.6m, max force 50 tons ACCESSORIES: automatic thickness control system, loading unloading system, injection head automatic handling system, injection hole vision system.

12 Some significant works Germany

13 Some significant works Germany PRODUCT: test panels (laboratory) FOAMING TECHNOLOGY: open mould and closed injection. Pentane PRESS TYPE: single trolley press PRESS PLATENS DIMENSIONS: 10.2X1.5m; max force 380 tons ACCESSORIES: no pit architecture, adjustable working level, injection heads holders, moulds and demoulding system, panel handling system

14 Some significant works Germany

Manni SpA Some significant works Germany PRODUCT: refrigerated trucks = wall, side, roof, front end and doors panels FOAMING TECHNOLOGY: open mould and closed injection.

15 Manni SpA Some significant works Germany PRODUCT: refrigerated trucks = wall, side, roof, front end and doors panels FOAMING TECHNOLOGY: open mould and closed injection. Pentane PRESS TYPE: trolleys presses (n. 3) and 2+2 (n. 2) PRESS PLATENS DIMENSIONS: up to 18x3.4m for bigger panels, 3x3.5m for front end and doors; max force up to 1400tons, min force 185 tons ACCESSORIES: adjustable working level, injection heads holders, moulds and demoulding system.

16 Some significant works Germany

Some significant works Denmark PRODUCT: Pu profiles for windows frame FOAMING TECHNOLOGY: open mould pouring. Pentane PRESS TYPE: fixtures recirculation FIXTURES DIMENSIONS: 6.

17 Some significant works Denmark PRODUCT: Pu profiles for windows frame FOAMING TECHNOLOGY: open mould pouring. Pentane PRESS TYPE: fixtures recirculation FIXTURES DIMENSIONS: 6.5x0.8, passive fixtures able to work with 3.5bar pressure (PU expansion) ACCESSORIES: fixtures handling systems, foaming heads automatic handling, release agent gun handling system.

18 Some significant works Denmark

Manni SpA VACUUM ASSISTED INJECTION In closed injection pouring, what if the injected cavity is maintained at certain level of controlled vacuum during injection and reaction, and is used a tailored

19 Manni SpA VACUUM ASSISTED INJECTION In closed injection pouring, what if the injected cavity is maintained at certain level of controlled vacuum during injection and reaction, and is used a tailored polyurethane formulation? The results obtained together with DOW Chemicals are: Demoulding time shortened by 30% Material saving of about 3 to 4% Insulation improvement of about 4% Better filling of the cavity and higher quality of the panel

20 VACUUM ASSISTED INJECTION - STATE OF THE ART AND NEW SOLUTIONS Manni, Cannon, DOW & MISA introduced V.A.I. in late 1990 s

21 VACUUM ASSISTED INJECTION - STATE OF THE ART AND NEW SOLUTIONS Vacuum system plant A Vacuum pump B Proportional Valve C Control PLC D Pressure transducer E Vacuum ducts F Connections G Inner walls. A B C E F G D

22 VACUUM ASSISTED INJECTION - STATE OF THE ART AND NEW SOLUTIONS F G H

VACUUM ASSISTED INJECTION - STATE OF THE ART AND NEW SOLUTIONS LIMITS OF THE CURRENT SYSTEM A dedicated press is needed, designed for the use of vacuum The platen

23 VACUUM ASSISTED INJECTION - STATE OF THE ART AND NEW SOLUTIONS LIMITS OF THE CURRENT SYSTEM A dedicated press is needed, designed for the use of vacuum The platen length cannot be fully exploited A rather complex injection device is used Explosion-proof vacuum pump when using Pentane The control of vacuum is not energy-optimized.

24 VACUUM ASSISTED INJECTION - NEW SOLUTIONS THE NEW MANNI 2.0 RETROFITTING KIT From now on, it becomes possible to retrofit a normal, not prepared press: so now it s possible to install a kit which make your press able to run with vacuum taking all the advantages of this technology and avoiding all the troubles of heavy modifications.

25 VACUUM ASSISTED INJECTION - NEW SOLUTIONS THE NEW MANNI 2.0 RETROFITTING KIT - CONCEPT Vacuum plant Vacuum unit Press platens Cavities to inject Injection hole Panne llo 1 Panne llo 2 Vacuum moulds

26 VACUUM ASSISTED INJECTION - NEW SOLUTIONS THE NEW MANNI 2.0 RETROFITTING KIT - COMPONENTS VACUUM UNIT, where the vacuum is generated and controlled this includes vacuum pumps, control valves, sensors, control hardware and software. The unit can control the level of vacuum in the cavity, the duration of the process and can store different recipes according to different kind of panels production, with optimized parameters

27 VACUUM ASSISTED INJECTION - NEW SOLUTIONS THE NEW MANNI 2.0 RETROFITTING KIT - COMPONENTS VACUUM PLANT, it simply connects the vacuum up to the cavities to be injected. With quick connections we are able to respect the normal movement of the press and the press platens

28 VACUUM ASSISTED INJECTION - NEW SOLUTIONS THE NEW MANNI 2.0 RETROFITTING KIT - COMPONENTS VACUUM MOULDS (SIDE MOULDS OR PROFILES), these items usually create the shape of the panel: dimensions and thicknesses; now they have additional functions bringing vacuum inside the press cavity. 1. Quick connections for connecting the cavity to the vacuum plant 2. Vacuum distribution in the whole cavity 3. Flexible configurability: it s possible to manage with vacuum both the single panel on the press platen or even multiple panels production 4. Special injection holes able to maintain the vacuum level even at the insertion of the injection head

29 VACUUM ASSISTED INJECTION - NEW SOLUTIONS THE NEW MANNI 2.0 RETROFITTING KIT - COMPONENTS

30 VACUUM ASSISTED INJECTION - NEW SOLUTIONS THE NEW MANNI 2.0 RETROFITTING KIT - CHEMISTRY Process Variables and Panel Properties obtained with PASCAL PRO Technology on Retrofitted Cannon Manni Plant Property Unit PASCAL PRO Free Rise Density pcf [kg/m 3 ] 1.81 [28.2] PASCAL PRO Panel Thickness Applied Density (mean) in [mm] pcf [kg/m 3 ] 6 [150] 2.22 [35.5] 8 [200] 2.18 [35] DOW Technology for V.A.I. Demolding Time min Compressive Strength psi [kpa] [ ]

31 VACUUM ASSISTED INJECTION - NEW SOLUTIONS THE NEW MANNI 2.0 RETROFITTING KIT - CONCLUSIONS Manni 2.0 Kit allows to use the V.A.I. technology on existing polymerization plants Metering & mixing side may remain unchanged Advantages can be obtained with a very short production stop for modifications.

32 STATE OF THE ART IN EQUIPMENT FOR DISCONTINUOUS PANELS MANUFACTURING MANNI PRESSE The dry side of polyurethane Thank you for your attention! Cristiano Ligabò Manni Presse

State of the Art in Equipment for Polyurethane Formulation and Injection using: PENTANE, METHYLAL, METHIL FORMATE, HFOs, WATER

State of the Art in Equipment for Polyurethane Formulation and Injection using: PENTANE, METHYLAL, METHIL FORMATE, HFOs, WATER Mauricio Schmuziger Schmuziger Representacoes Fabrizio Brambilla Impianti