®Manni SpA STATE OF THE ART IN EQUIPMENT FOR … · THE NEW MANNI 2.0 RETROFITTING KIT - CHEMISTRY...

HCFC ALTERNATIVES FOR THE FOAM SECTOR TECHNOLOGIES AND EQUIPMENT SOLUTIONS

23-24 July, 2014 Chapecò(SC) Brazil

STATE OF THE ART IN EQUIPMENT FOR DISCONTINUOUS PANELS

MANUFACTURING

Cristiano Ligabò Manni Presse

MANNI PRESSE

The dry side of polyurethane

®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

®Manni SpA



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 pouring

®Manni SpA

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.

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 Press

Platens

Cavities to

be filled

Lateral

frame

Injection

head



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

®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 step in multiplepoints) + tilting. Pentane: Ex presses

PRESS TYPE: trolley presses, n.°7 2+2 (two trolleys in press each cycle) and n.°2 1+1 (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

®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 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,

®Manni SpA



Some significant works – UK

®Manni SpA



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.

®Manni SpA




®Manni SpA




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

®Manni SpA




®Manni SpA




PRODUCT: refrigerated trucks = wall, side, roof, front end and doors panels

FOAMING TECHNOLOGY: open mould and closed injection. Pentane

PRESS TYPE: trolleys presses 2+0.5 (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.

®Manni SpA




®Manni SpA



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.

®Manni SpA



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 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

®Manni SpA



VACUUM ASSISTED INJECTION - STATE OF THE ART AND NEW SOLUTIONS

®Manni SpA

Manni, Cannon, DOW & MISA introduced V.A.I. in late 1990’s




®Manni SpA

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

F

E

G

D




®Manni SpA

H

F

G




LIMITS OF THE CURRENT SYSTEM

®Manni SpA

• 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.



VACUUM ASSISTED INJECTION - NEW SOLUTIONS

THE NEW MANNI 2.0 RETROFITTING KIT

®Manni SpA

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.




THE NEW MANNI 2.0 RETROFITTING KIT - CONCEPT

®Manni SpA

Pannello 1

Pannello 2

Vacuum unit Vacuum

plant

Vacuum moulds

Press platens

Injection hole

Cavities to inject




THE NEW MANNI 2.0 RETROFITTING KIT - COMPONENTS

®Manni SpA

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





®Manni SpA

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





®Manni SpA

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





®Manni SpA




THE NEW MANNI 2.0 RETROFITTING KIT - CHEMISTRY

®Manni SpA

PASCAL™ PRO DOW Technology for V.A.I.

Process Variables and Panel Properties obtained with PASCAL™ PRO Technology on Retrofitted Cannon Manni Plant

Property Unit PASCAL™ PRO

Free Rise

Density

pcf

[kg/m3]

1.81

[28.2]

Panel Thickness

in

[mm]

6

[150]

8

[200]

Applied Density

(mean)

pcf

[kg/m3]

2.22

[35.5]

2.18

[35]

Demolding Time

min 30 45

Compressive

Strength

psi

[kPa]

30.5-31.9

[210-220]




THE NEW MANNI 2.0 RETROFITTING KIT - CONCLUSIONS

®Manni SpA

• 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.



STATE OF THE ART IN EQUIPMENT FOR DISCONTINUOUS PANELS

MANUFACTURING

Cristiano Ligabò Manni Presse

MANNI PRESSE

The dry side of polyurethane

®Manni SpA

Thank you for your attention!

®Manni SpA STATE OF THE ART IN EQUIPMENT FOR … · THE NEW MANNI 2.0 RETROFITTING KIT - CHEMISTRY...

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