VarioLineSystems. innovative material technologies

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1 VarioLineSystems innovative material technologies

2 VarioLine : This innovative lightweight construction system opens new horizons for your company. At VarioLineSystems we combine the most important material characteristics with the highest quality levels to provide you with a superior product. Production facility Dresden, Germany 2

3 < Our head office and our primary production facility are now situated in the high technology centre of Dresden. Worldwide unique process Finally, users of plastic sheets, plywood and sandwich lightweight construction elements have an alternative: VarioLine, an innovative lightweight construction system made of solid structural outer layers and a foamed centre core thereby uniting all the advantageous characteristics of plastic and wood. The result: high stiffness and impact strength and exceptionally low weight. As the name VarioLine implies, our specially developed process technology enables us to vary material compositions to match the customer requirements. That is what makes VarioLine so unique. International acceptance Industrial and distribution customers in Europe, North America and overseas are convinced of the superior quality of VarioLine as a multifunctional material platform and have improved product performance through the use of VarioLine in a host of applications. The following pages will give you an overview of what makes VarioLine so versatile and reliable, as well as presen 3

4 Leading edge: The right idea is the smartest step forward. VarioLine fulfils high demands but keeps its variability... Challenging new possibilities Until recently you had to decide between wood and plastic two equally important materials. It took great effort to combine or add the characteristics of the two material worlds. That s over now. With vision and ingenuity a new process technology was developed and perfected that allows us to transform homogenous polymeric recipes into an exceptionally light, and at the same time rigid and weather resistant matrix. This technology unites the best characteristics of wood and plastic in one product: VarioLine. Since VarioLine is meant to be a material platform, it is designed to be custom made to include, or add further features important to enhance our customers success. Integral foamed sheets up to 4.5 m 2 (47.5 f 2 ) Even, textured surface. Thickness tolerance of +/- 0.2 mm ( ). The defined and precisely adjustable multiphase construction produced from one material forms a homogenous sandwich structure. Load carrying solid structural outer layers provide the mechanical properties the foamed core reduces the specific weight. Pore-free solid skin. 4

5 Increase of structural rigidity at constant weight as function of the degree of foaming Degree of weight reduction together with moderate loss of stiffness. You set the objectives Unlike conventional production methods, our process technology by definition offers a high degree of flexibility. This provides you with the possibility to consider and define important characteristics such as robustness, weight, rigidity, stiffness, UV resistance, colour,. before production begins. We are able to design the optimal process and material composition for your product application from the very beginning and thereby assure the produced material has the right set of parameters inside to outside. The one step production of VarioLine provides the ability to react promptly to incoming customer demands. An Example? Within 8 weeks we were able to design, produce and deliver an extremely light and stiff VarioLine product for concrete formwork to an Asian customer that was able to meet his high national standards. This customer is today the only company that can supply plastic formwork components in the dimension x 900 mm (70 x 35 ) weighing less than 25 kg (63 lbs). Solid outer layers enhance load carrying ability. High tensile and impact strength are the key skin properties. Precise control of transition (see left). Closed cellular core Besides reduction of density and weight, the cellular cores high compression strength lets it function as a stress transmission layer in VarioLine. Closed cell walls inhibit any capillary effect, not allowing the absorption of water (see below). 5

6 Focused: Our experts constantly look for new challenges. Continuous application orientated development of the VarioLine technology delivers innovative and market driven products. Perspectives VarioLineSystems evolved from a plastic research and development company. We have constantly advanced our unique production process through intensive materials research and customer driven project application. VarioLineSystems has grown into a leading high-tech company with efficient management, highly motivated and skilled employees, dynamic product development, high potential and an excellent outlook for the future: We are a now a leading company in the production of lightweight foamed polymer construction systems. Temperature control 6

7 Leading edge technology VarioLine lightweight systems are manufactured by high-pressure injection moulding. The entire production process is controlled with our self-developed software. By monitoring all process parameters through closed loop systems control we are able to automatically adjust all relevant parameters online in real-time. High injection speeds and the ability to plasticise extremely high shot sizes enables us to produce stress free parts with a size of up to 4.5 m 2 / 47.5f 2 while keeping within an overall thickness tolerance of < 0,4 mm / Short adjustment time for hardware and process software permits us to react swiftly to new material requirements and gives us an excellent position for future product development. Partnerships Our goal is to expand our position as a market leader and to establish VarioLine as a universal polymer material in the field of lightweight construction by co-operating with leading international partners. Using thermoplastic materials (PP; PE; PS; PA) of renowned global resin producers we will continue to develop new product generations that are easily applicable in practice. This puts us and our customers in good position from which new product ideas can originate with the highest possible quality. The latest research and development areas of the VarioLine technology include the introduction of a scratch resistant material, in-mould lamination by injecting between decorative surface materials and the application of the technology beyond sheets in 3D plastic parts. VarioLine is produced by ultra-modern, globally unique injection moulding equipment. 7

8 Variable: Whatever the demand, VarioLine fulfils it. VarioLine is as durable as solid plastics, lighter than plywood and exceptionally versatile Hard structural skin lightweight core VarioLine is a compact multiphase system generated from homogenous resins. Highly dense thickness controlled solid structural outer layers are the key factor in providing mechanical stability of the material (double T-Beam-principle). Lightweight and incompressible foam cells form the centre structure between the skin layers. When benchmarking VarioLine with solid plastic sheeting it can boast almost 90% of the bending strength while being 40 to 60% lighter. Fully automated sheet handling 8

9 Mutiple utility: the decisive advantage Higher stability through multiphase system Less weight through a stable foam core Higher load capacity.. through improved stiffness/impact Longer life expectance. through high durability Lower costs through reduced material input Higher efficiency..... through optimal material distribution Prompt results through a single step production process Large format many colours The standard VarioLine models are x mm (80 x 65 ) and x mm (98 x 58 ) and 6 to 22 mm (1/4 to 7/8 ) thick. We also offer CNC-precut service to customers. With our technology we can produce any colour. Our standard colours are white, cream, light grey, dark grey and black. Optional stock colours include yellow, red, green, blue. Custom colours are available on request. The sheets are coloured through. Your call, our answer Many important features such as sheet thickness, density, colour, weight, surface appearance and adhesion, stiffness, impact resistance and durability are adjustable to suit any application. You tell us which of the VarioLine family of materials you want and we will modify the variables to meet your request. VarioLine is produced from a combination of high-purity polymers and reinforcement materials, custom designed to meet your needs. 9

10 Reliable: VarioLine stays strong even under extreme loads. VarioLine is hard to break, impact and chemical resistant as well as weather proof. You determine the level of performance. High load bearing capacity To match the requirements presented by our customers we design material and process parameters using only the highest quality thermoplastic materials (PP, PE, PS, PA) and material additives. The result is an optimal sheet quality that, even when slightly damaged, remains fully functional. Extreme break resistance and high impact strength down to temperatures of 25 C / 13 F can be achieved through the use of very long-chain polymers. This is essential for dynamically stressed parts and constructions in vehicles or packaging. This creates new possibilities for you and your customers. The ability to increase stiffness by more than 200% is achieved by embedding a complex crystal matrix or fibres as reinforcement in the plastic resin. This results in materials that are particularly strong and used within the concrete formwork and scaffolding industries, resulting in far less deflection under high load situations (Flex-Modulus of up to 6,000 N/mm 2 (700,000 PSI). 10

11 VarioLine during testing: Accelerated aging test and FEM-analysis. Low weight With an overall density of just 440 kg/m 3, a square meter of VarioLine weighs only 6 kg (example: VarioLine ultra light, 15 mm), and is up to 35% lighter than plywood and up to 50% lighter than solid plastic sheeting. A square foot of the same material would weigh just 1.25 lbs. Water resistant surface Being free of pores and easy to clean, VarioLine is used in many visible areas. As the closed cell foam core does not absorb water, VarioLine is impervious to rot. Sealing the edges is certainly possible using conventional equipment and should be considered where looks are important. All VarioLine HDPE and PP resins are applicable for use in the food industry and have FDA approval. Extreme durability VarioLine resists salt water, moisture, vapour and steam, as well as varying levels of UV-exposure as determined by the customer. Acids, bases and other aggressive chemicals do not affect the sheet. As such, the durability of VarioLine is far superior to that of wood based sheets. Even without special fire retardant additives, VarioLine complies with the B2 fire rating, with the optional ability to achieve a B1 rating being available through custom material processing. High-precision guidance of the up to 45 t heavy mould sections. 11

12 Fuss free fabrication: VarioLine processing and handling has never been easier. You can drill, cut, mill, weld, rivet and screw VarioLine, and recycle it. Safe handling VarioLine is easy to handle. You can process it using standard tools and tooling. Just as with wood it can be nailed, riveted, cut and sawed, milled and drilled. Unlike wood, with VarioLine you can connect single sheets for seamless flooring or large side walls by simply welding VarioLine together using standard heat sword or hand welding equipment. Thermal bending is also possible. Gluing, painting, printing and labelling can be done without any preparation when using polystyrene VarioLine. As with all polypropylene and polyethylene based materials VarioLine PP and PE sheeting requires pre-treatment of the surface. 12

13 Screwing, drilling and sawing VarioLine can be machined without restrictions. Safe Disposal Whatever you decide to make from VarioLine it will retain material integrity until the very end. VarioLine is not only extremely durable and environmentally friendly, but it is also recyclable. In clean condition the material off-cuts can be recycled. Leftovers can be disposed together with the regular domestic waste. Please contact your local authorities as recycling opportunities may exist in your area always a better choice. CNC-pre-cutting service 13

14 Profitable: VarioLine always leads to exceptionally good results. The VarioLine technology continues to replace conventional wood and plastic sheeting in many areas and the number of applications grows everyday... VarioLine is universal Since the introduction of VarioLine technology and the start of large-scale production the material system has proven its abilities in many different, often extreme conditions and never fails to impress its users. Process control 14

15 Successful application of VarioLine in Marine industry Partitions, decks and soles, seats and backs, upholstery, doors and hatch covers, boxes, bulkheads, swimming platforms, etc. Vehicle and trailer construction Interior accessories, gas storage lockers and boxes, vehicles for public, passenger and industrial transportation or goods and services, livestock trailers, toilet components and compartments and luggage racks for motor homes; walls and floors for trailers etc. Agriculture Partitions, pig pens, horse and livestock barns and containment areas, chicken and turkey cots etc. Playground and leisure equipment Walls and floors, slides, swings, carousels, climbing walls etc. Custom packaging and transport Collapsible boxes, returnable transport systems, bag in box etc. Specially designed product families: VarioBoard production pallets for concrete block moulding industry VarioPanel panel system for visible concrete formwork construction VarioCor highly durable core material for reinforced composite systems The applications are limitless... Stage construction, conveyor components, scaffolding, painting booths, machine housings and guards, medical equipment and technology, stands and booth construction for fairs and exhibitions, sanitary products, sauna construction, oscillating doors, shaft covers, control box bottoms, tanks, panelling, advertising mediums, bank protection, ventilation systems etc. The VarioLine success story continues. New application ideas are constantly developed. Why not yours? We look forward to working with you on new applications. VarioLine excels by being capable in so many areas. 15

16 VarioLine lightweight construction systems Durable, stable and variable - inside and outside. And always designed to meet your needs, and the needs of your customer. Further information is available upon request or visit our web site 1) Technical Data Sheets 2) Material Safety Data Sheets (MSDS) 3) Processing and Handling Guidelines 4) Chemical Resistance Data VarioLineSystems innovative material technologies Headquarters VarioLineSystems GmbH Hennigsdorfer Strasse 25 Geb. 102 A D Dresden Germany Tel.: +(49) 3 51 / Fax: +(49) 3 51 / sales@varioline-systems.com Nordeuropa VarioLineSystems Per Haakonsen Box 2156 Hydro Menstad Næringspark N Skien Norway Tel.: +(47) 35 / Fax: +(47) 35 / haakonsen.per@varioline-systems.com North America VarioLineSystems David Jones 22 Hunt Village Crescent London, Ontario N6H 4A3 Canada Tel.: +(1) 519 / Fax: +(1) 519 / jones.david@varioline-systems.com 12/02 Auflage: zebra Werbeagentur GmbH Dresden