{"id":39009,"date":"2023-09-29T09:19:29","date_gmt":"2023-09-29T07:19:29","guid":{"rendered":"https:\/\/panelsandwich.org\/03-production\/"},"modified":"2026-09-24T09:11:42","modified_gmt":"2026-09-24T07:11:42","slug":"03-production","status":"publish","type":"page","link":"https:\/\/panelsandwich.org\/en\/sandwich-panel-technical-information\/03-production\/","title":{"rendered":"03 – Production"},"content":{"rendered":"
\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\n
\n
\n

TECHNICAL INFORMATION \u00b7 PRODUCTION<\/p>\n

Sandwich panel manufacturing: production process<\/h1>\n

Sandwich panel manufacturing combines chemical dosing, forming of the metal faces, formation or incorporation of the core, pressing, curing, cutting, stacking, and packaging. The original technical page distinguishes between batch systems and continuous production lines. <\/p>\n

This version preserves all the historical technical parameters of the original page, but expressly identifies the data that must be interpreted as process reference and not as universal performance of any current factory or panel.<\/p>\n

RIM process \u2193<\/a>Continuous line \u2193<\/a><\/div>\n <\/div>\n
\"Technical<\/div>\n<\/div>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\n
\nRIM and mixing<\/a>Pumps<\/a>Head<\/a>Facilities<\/a>Batch production<\/a>\nContinuous production<\/a>Cutting and stacking<\/a>Historical parameters<\/a>Mineral wool<\/a>Adhesives<\/a>\n<\/div>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t

Sandwich panel manufacturing principles<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Manufacturing combines continuous materials\u2014such as coil sheet\u2014with a core that can be formed chemically during the line or incorporated as a rigid material previously produced. Process control seeks to maintain mixing, adhesion, geometry, and finish in a repeatable manner. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t\t\t\t\n
\n
Reactive material<\/div>

Polyol + polyisocyanate<\/h3>

Manufacturers receive liquid components and convert them into polyurethane through a controlled reaction, together with additives defined by formulation.<\/p><\/div>\n

Dosing<\/div>

Precision and temperature<\/h3>

The viscosity and proportion of the components affect the mixture. For this reason, tanks, pumps, and control circuits are a critical part of the process. <\/p><\/div>\n

Formation<\/div>

Continuous or batch<\/h3>

Manufacturing can be carried out in closed molds per panel or in automatic lines where the panel is formed, cured, cut, and stacked continuously.<\/p><\/div>\n<\/div>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t

Materials and Finished Product<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\n

Beyond the process overview, it is useful to see how materials become the finished product and how geometry changes according to the application.<\/p>\n

\n
\"Technical

Panel Section<\/h3>

The final geometry integrates the two faces, the insulating core, and the joint formed during production.<\/p><\/div><\/div>\n

\"Stacked

Finished and Stacked Panel<\/h3>

Edge finishing and package stability are important before transport.<\/p><\/div><\/div>\n

\"Handling

Product Handling<\/h3>

Length, rigidity, and surface finish determine the unloading and handling of the manufactured panel.<\/p><\/div><\/div>\n<\/div>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t

Reaction injection molding (RIM): dosing and mixing<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\n

The original page calls reaction injection molding (RIM)<\/strong> the process based on a high-pressure foaming unit. In this system, polyol, polyisocyanate, and additives are combined to generate a reactive mixture capable of forming microcellular or microporous foams in reduced cycle times. <\/p>\n

Storage tanks and day tanks<\/h3>\n

The main components and additives\u2014stabilizers, flame retardants, pigments, and others\u2014are kept in storage tanks and transferred before production to feed tanks or day tanks<\/strong>.<\/p>\n

Thermal control is important because a temperature variation, especially in polyols, modifies viscosity. The source describes double-walled tanks, with stirrer and temperature control circuits to maintain process conditions as constant as possible. <\/p>\n

Recirculation before injection<\/h3>\n

Before each mixing and filling cycle, the components recirculate in the required proportions and at the required pressure. Electronically controlled actuators divert the flow from the recirculation circuit to the injection circuit and then restore recirculation. <\/p>\n

Context:<\/strong> the description corresponds to the technical system recorded in the original page. Formulation, temperature, pressure, and machine architecture must be verified for each actual production line. <\/div>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t

Dosing pumps: precision, flow rate, and limitations<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\n

Dosing must be repeatable and precise. The objective of the pumps is to transport from the day tanks to the foaming head the correct quantity of each component, maintaining the intended mixing ratio. <\/p>\n

The historical source cites flow rates of 12 to 150 liters per minute<\/strong> for axial piston pumps, highlighting their low noise level and precision. It also indicates two limitations: high-viscosity liquids and the presence of abrasive fillers. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t\t\t\t\n
\n
Element<\/th>Historical data<\/th>Function \/ limitation described<\/th><\/tr><\/thead>
Dosing pumps<\/td>12\u2013150 L\/min<\/td>The source cites axial piston pumps of high precision to reproduce mixing ratios.<\/td><\/tr>\n
Viscosity<\/td>Qualitative limitation<\/td>Axial piston pumps have limitations when liquids have high viscosities.<\/td><\/tr>\n
Abrasive fillers<\/td>Not recommended in the described configuration<\/td>The source warns that liquid components must not contain abrasive fillers for this pumping system.<\/td><\/tr>\n
Head nozzles<\/td>100\u2013150 m\/s<\/td>Historical velocity cited for the components through the injection nozzles.<\/td><\/tr>\n<\/tbody><\/table><\/div>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t

High-pressure foaming head<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\n

The foaming head is the point at which the components meet and mix. The technique described uses high-pressure impingement<\/strong>: the liquids are injected into the mixing chamber and their kinetic energy promotes intimate mixing. <\/p>\n

The original page cites component velocities in the nozzles of approximately 100\u2013150 m\/s<\/strong>.<\/p>\n

Piston cycle and recirculation<\/h3>\n
  1. In recirculation position, the components return to the tanks through small ducts.<\/li>
  2. When the piston is withdrawn, the mixing chamber opens and the components impinge on each other.<\/li>
  3. When the piston advances again, mixing is interrupted.<\/li>
  4. Recirculation is restored and the remaining reactive mixture is removed from the chamber.<\/li><\/ol>\n

    This mechanism allows synchronization of mixture supply, especially in batch processes.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

    \n\t\t\t\t\t\t
    \n\t\t\t\t\t
    \n\t\t\t
    \n\t\t\t\t\t\t
    \n\t\t\t\t\t

    Production facilities and equipment<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t

    The system described integrates the mixing\/injection machine, the mold or press, and the auxiliary equipment necessary to form, cut, and handle the panel.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

    \n\t\t\t\t\t\t\t\t\t\n
    \n
    Equipment<\/th>Function within the system described<\/th><\/tr><\/thead>
    Feed tanks<\/td>Keep the components available under controlled thermal conditions.<\/td><\/tr>\n
    Dosing \/ recirculation pumps<\/td>Control flow rate, proportion, and circulation prior to mixing.<\/td><\/tr>\n
    Foaming head<\/td>Mixes the components by high-pressure injection.<\/td><\/tr>\n
    Mold or press<\/td>Defines geometry and maintains the faces during expansion and hardening.<\/td><\/tr>\n
    Auxiliary equipment<\/td>Profiling, heating, cutting, stacking, packaging, and automation according to line type.<\/td><\/tr>\n<\/tbody><\/table><\/div>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
    \n\t\t\t\t\t\t\t\t\t\n
    \n

    Batch system<\/h3>

    Each panel is manufactured in a closed mold of the final dimensions.<\/p>