Latrobe, Pennsylvania -- OMS Group claims it is helping sandwich panel manufacturers save hundreds of thousands of dollars per year by installing more energy- and chemical-efficient technology.
According to the Milan, Italy-headquartered polyurethane machinery group, manufacturers of flexible-faced, insulated roofing panels have reported a 10-percent drop in chemical costs and significant savings in maintenance and energy savings after upgrading existing production lines to new high-speed OMS laminators, said Mark Clark, general manager of Polyurethane Process Industries. PPI is OMS's exclusive distributor in the US.
"Several US and European panel manufactures replaced their old mixheads and chain-driven laminators with new OMS high-pressure mix heads, high-pressure heat exchangers, and gear-driven double-belt conveyors," Clark said, in a 12 May statement. "The whole OMS laminator is fully enclosed to inhibit heat loss during the curing process. The conveyor is also chainless, which means significantly lower maintenance cost and less friction, so OMS can use smaller drive motors that use less energy."
Clark said other manufacturers of continuous flexible- and rigid-faced sandwich panels could make similar savings with the same OMS mixhead and laminator upgrades.
* A lay-down area where three self-cleaning, recirculating mixheads distribute multiple streams of reacting foam onto a flexible or rigid substrate. Pneumatically controlled nozzles on the high-pressure mixheads automatically adjust to maintain a set pressure, PPI notes. The mixheads improve chemical utilisation by: better control of chemical temperature and pouring pressure; dynamic blending of variable amounts of polyol, catalyst, blowing agent and other additives; impingement mixing; and foam distribution.
* High-pressure heat exchangers near the mixheads that give more accurate control of chemical temperature where needed.
* A double-belt conveyor that precisely maintains the required dimension of the finished panel as it transports the substrate and foam core through the curing process. Automatic adjustment of the upper belt position precisely maintains or varies panel thickness without shutting down the line to insert calibration spacers. Hot air circulates within the conveyor, which is enclosed within a thermally insulated tunnel to conserve heat and energy.
"This technology is standard on OMS continuous panel lines," Clark said, adding that, "The new mixheads and high-pressure heat exchangers typically pay for themselves in a year by reducing the amount of scrap and chemicals used."