Sandvik casting units for solid surfaces and engineered stone
In-depth engineering expertise in continuous sheet production In 1901, our company produced the world s first steel conveyor belt. Less than 20 years later, our steel belts first started rolling on a double belt press and they have been at the heart of press and casting systems ever since. We pioneered the development of steel belt production lines for both acrylic and polyester resin applications and today lead the way in the design of single and double belt systems for the production of: Solid surfaces based on acrylic or polyester resin Engineered stone based on polyester resin, PU, epoxy or acrylic Other applications for our systems include an almost unlimited range of compounds (e.g. polymer concrete, mineral casting etc. combined with binders such as vinyl ester, phenolic resin etc.) The inherent qualities of a steel belt strength, durability and high resistance to wear and corrosion deliver a long operational life for an excellent return on investment, while the flat, hard and smooth surface ensures a high quality finish. While steel belts are without parallel in terms of delivering the high pressures required to process many sheet materials, certain products or production stages require less pressure. Here, Teflon-coated belts can be used to significantly reduce investment costs, while also offering outstanding thermal and/or anti adhesion properties. Double belt units Versatile adjustable product width Narrow thickness tolerance Smooth, high quality product surface Highly efficient with symmetric heating and cooling Minimal release of solvents for environmental protection No need for protection films Single belt units Fixed product width Versatile variable product thickness Economical continuous production Protection films required for certain resins 2
Efficient production by combining multiple processes polymerizing, curing and cooling into one continuous process FILM RE-WINDER PolYMeRiZAtion Cooling CuRing Cooling FILM RE-WINDER Temperature Cutting Product Air Systems are available in the form of single or double belt units to meet different process needs. MODULAR DESIGN ENABLES MULTIPLE PROCESSES IN A SINGLE SOLUTION our modular approach to system design means we can combine different types of processes into one continuous production process. This multi-stage approach, incorporating controlled polymerization, curing and cooling in a single system, enables the development of highly efficient, environmentally-friendly process solutions. ADVAntAges of sandvik tps CAsting systems include: Creating precise heat profiles via multi-staged zones of different temperatures Heating, reaction, calibration, cooling and confection in one in-line process High productivity Adjustment of process profiles for different products High accuracy and superior surface quality Variation of product width and thickness 3
End-To-End SHEET casting SoLUTIonS for EngInEErEd STonE / ArTIfIcIAL marble 1 2 3 4 The versatility of our system design the ability to tailor each separate stage of production to specific product requirements enables us to provide sheet casting solutions for virtually any requirement. we can also integrate a full range of up- and downstream equipment, from initial processing and feed options to cutting and stacking solutions. 4 production lines can be based on single or double belt technology. Advantages of double belt systems include: Symmetric conditions (processed from both sides) precise thickness calibration Simple variation of product width EFFICIENT, CONTROLLED PROCESSING WITH ADM AND SANDVIK TPS UNITS our systems are designed and built in close co-operation with Adm-ISobLoc gmbh, one of the world s leading manufacturers of metering, dosing, mixing and degassing equipment to the composites industry. The manufacturing process begins with dosing 1 and mixing 2 of the constituent materials (resin, filler, additives, colour and chips); advice on raw materials and ratios can be provided as required. This stage can also include degassing 3. The compound product is then cast 4 on the belt.
9 10 8 7 6 5 The width of the product is defined by the use of side retainers and the layer is calibrated to the required thickness before being transported into the main system. The product then passes through a series of zones: first heating and polymerization 5, then cooling 6 followed by hardening/curing 7 and finally a second cooling 8 stage. heat curing systems require a precise temperature the overall profile is critical to the quality of end product and the different zones are heated by air made up by heat exchangers in a heating/ cooling system. 1 Dosing 6 Cooling 2 Mixing 7 Hardening/curing 3 Degassing 8 Cooling 4 Casting 9 Cutting 5 Heating/polymerization 10 Finishing The thickness of the product taking into account the shrinking effect is easily adjusted by means of a high precision gear and spindle system that sets the gap between upper and lower belt. After being discharged from the belt system, the sheet is cut into tiles 9. The tiles are then ready 10 for post-curing and any additional finishing processes such as sanding or polishing. After finishing the tiles are then cut to final size ready for packaging. 5
Design flexibility to meet specific performance parameters Our efficient, easy-to-manage casting line systems can be used to process a whole range of resin-based products The performance and success of our casting solutions are the result of decades of experience in this specialist field, together with the close partnerships we have established with leading names from across the chemical and casting equipment industries in North America, Europe, Asia and the Middle East. Sheet casting based on single or double belt casting machines offers a range of benefits over other methods: Improved efficiency of continuous production Low tolerances on film/sheet thickness compared to single mould production High clarity and low stress in the formed product Perfect surface properties using Sandvik mirror-polished steel belts Thick slab products are possible multiple process zones on the same machine Complete polymerization 6
Regional productivity centers Choose to work with Sandvik TPS and you benefit from the flexibility, responsiveness and customer focus of a mid-size company, backed up by the strength and stability of the global Sandvik Group. This means you can trust us to provide a complete service, from consultancy, pilot plants and testing, through to manufacture, installation, commissioning and ongoing service. This focus on customer support is reflected in the investment we have made in our regional productivity centers located in Germany and Japan. Whether you re looking to carry out initial tests or undertake pilot production trials, we invite you to do so using your own products on the single belt or double belt units available here at our dedicated productivity centers. 7
Sandvik TPS Composite Solutions Daimlerstr. 8, 73037 Göppingen, Germany Phone +49 7161 98432-0 Fax +49 7161 98432-115 Email: info.stps@sandvik.com www.processsystems.sandvik.com S-PS701-B-ENG-15