Hennecke
- Offer Profile
- There is not only one single special property that is responsible for the worldwide success story of polyurethane. Polyurethane products have as many properties as shapes and, therefore, they offer the PU processor almost unlimited possibilities. Plastics have long been an integral part in many areas of modern life. For more than six decades, Hennecke GmbH has been developing and designing high-class machine and systems technology as well as process technology for polyurethane processing.
Product Portfolio
Metering machines
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THE HEART OF POLYURETHANE PROCESSING
Mixing and metering without any quality compromise with machine technology for every conceivable and inconceivable application: for more than 50 years, metering machines from Hennecke have been synonymous with top quality polyurethane processing and have been the centrepiece of countless processing plants. The Hennecke lineup comprises modular configurable systems for small to large outputs with first-class metering pumps, a great choice of state-of-the-art mixheads and intelligent automation.
TOPLINE HK
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Modular high-pressure metering machines for countless applications
Globally, several thousand HK machines are successfully in use in almost all fields of application. The machine concept of the TOPLINE series comprises a sophisticated arrangement of the individual units, top-quality, first-class components, an ultramodern and user-friendly control system and state-of-the-art mixhead technology. The current TOPLINE generation is equipped with an intelligently revised machine concept and optimised standard features.
MICROLINE
- High-pressure metering machine for precisely metering small outputs
By opting for a MICROLINE, users will benefit from a two-component high-pressure foaming machine for precisely metering very small outputs ranging from 2.5 g/s to 130 g/s. The machine design and the major part of the modules are based on the successful TOPLINE high-pressure metering machines. MICROLINE systems are perfectly suited for PU casting and spraying applications. Most typically, the compact metering machine is used in the automotive industry or spray skin applications within the advanced PUR-CSM technology. Adapted to your process parameters, MICROLINE comes with extensive standard equipment right from the factory, including frequency-controlled motors, component temperature control and an intuitive touch-screen control system.
HIGHLINE
- Compact high-pressure metering machines for a wide range of applications
With the HIGHLINE, we supply users with a highly efficient high-pressure metering machine for two-component applications. HIGHLINE machines impress with their attractive price-performance ratio, but without any compromise in terms of metering accuracy, adherence to the formulation, or precise compliance with part weights. The selection of top-quality components and useful additional equipment options make it worthwhile to invest in HIGHLINE machine technology for countless possible applications in the field of two-component polyurethane processing. The HIGHLINE is not just efficient in terms of costs: Every HIGHLINE series metering machine is equipped as standard with an intelligent energy-saving concept that switches any components not required to standby mode. In addition to a sophisticated automation control system, the BLUE INTELLIGENCE package also includes a combination of various additional machine components, and is thus capable of reducing energy requirements by up to 50 percent.
QFOAM
- Compact high-pressure metering machines for standard applications
The machine concept of the QFOAM has been designed consistently as a series product that combines the advantages of high-pressure polyurethane technology with a convincing price/performance ratio. This ensures real added value and makes the extremely compact metering machines based on Hennecke's tried-and-tested technology an ideal alternative to low-pressure systems and their inherent disadvantages. The main uses of QFOAM machines are cold-curing flexible foam, compact systems, filling foam, integral skin foam, energy-absorbing foam and rigid insulating foam. Two QFOAM machine types are available: the QFOAM and QFOAM XL. The XL version stands out for its enhanced scope of equipment even for special applications.
STREAMLINE
- High-pressure metering machines for processing resin,
hardener and polyamide systems
Hennecke's STREAMLINE machine system is a tailor-made processing system for all common matrix systems used in fibre composite parts such as polyurethane or epoxide resin, hardener and also polyamide 6 raw material systems (cast nylon). It can be perfectly adapted to the demands of the individual production thanks to its modular design and the fact that it can be easily integrated into automated production lines. Right from the beginning, STREAMLINE metering machines come equipped with comprehensive standard parts such as a self-cleaning high-pressure mixhead and an intuitive touchscreen control system based on SIMATIC-PLC. Thanks to an efficient and reliable temperature control system for tanks and pumps using proven hot air technology, the STREAMLINE ensures that components are effectively heated and mix results are excellent even when outputs are low.
TOPLINE HT
- High-pressure piston metering machine for extreme requirements in the area of filled pur systems
The wear-resistant, reactionless HT metering system with tandem plunger pumps is suitable for extreme demands in various output ranges. HT piston metering machines are capable of processing filled and unfilled components in absolute conformity with the formulation both in a discontinuous and continuous operation. This means that the robust metering machines are for example qualified for processing polyols with different fillers, abrasive colour pigments or high-viscosity raw material systems. TOPLINE HT machines also offer major advantages in the processing of synthetic resin using the RTM method (Resin Transfer Moulding). Two machine types (HT80 and HT180) are available, covering an output range of 8 - 360 cm³/s. In addition to processing polyols with solid flame retardants for example, ammonium polyphosphate, melamine resin and expanded graphite the systems are also particularly suitable for processing polyols made of renewable raw materials, recycled polyols, polyols with fillers such as PUR regrind or abrasive fillers such as glass fibres, calcium carbonate, barite, abrasive colour pigments and highly viscous raw material systems.
TOPLINE HT500evo
- High-pressure piston metering machine for processing abrasive fillers in polyurethane systems
Common metering machines for liquid components which are equipped with high-speed piston pumps cannot withstand the high abrasiveness of solid fillers long-term. Especially for processing main components containing fillers, Hennecke has therefore developed the TOPLINE HT500evo metering machine with a low-wear plunger pump which produces even under highly abrasive conditions with high precision, repeat accuracy and endurance. The TOPLINE HT500evo has an attractive price-performance ratio and is suitable for parts weighing up to three kilogrammes, with an output of 100 - 500 cm³/s. One of the main applications of this device is the production of comfort flexible foam that is, for example, used in seats and cushions for vehicles, especially in public transportation. Another area of application of the TOPLINE HT500evo are rigid foam applications, as for insulation within the framework of fire protection class B2 in the construction industry. Hennecke offers the TOPLINE HT500evo as an independent 2-component metering machine or as a module device for retrofitting an existing TOPLINE metering machine. In addition to processing polyols with solid flame retardants for example, ammonium polyphosphate, melamine resin and expanded graphite the efficient metering system is also particularly suitable for processing polyols made of renewable raw materials, recycled polyols, polyols with fillers such as PUR regrind or abrasive fillers such as glass fibres, calcium carbonate, barite, abrasive colour pigments and highly viscous raw material systems.
TOPLINE HK-MF
- Optimised for multi-component applications in the manufacture of moulded foam products
Moulded foam lines rely on a further development of the TOPLINE type series. The "HK-MF" version has been optimised to meet the specific requirements of moulded foam production and is suitable for reliably processing up to six reactive components in a plant network. Users benefit from an extremely compact machine frame that incorporates all elements of a reactive component and, compared with the classical TOPLINE, scores points because the pipework has been significantly reduced. Combined with a temperature control system in the component feed line, this ensures very precise temperature control. When using two mixheads or two injection robots, the "HK-MF" is employed as a twin module. Especially when it comes to multi-component applications with up to twelve metering lines, this means once again that a considerable amount of precious production space is saved. Apart from the efficient raw material temperature control system, HQ axial piston pumps are included in the standard scope of delivery of the WKH unit. If desired, users can opt for state-of-the-art magnetic coupling technology and other features.
COLOURLINE
- High-pressure metering machine with multi-connect technology for fast and easy colour change for surface finishing
A tried-and-tested field of application for polyurethane and polyuria system is the surface finishing of decorative elements in the automotive sector, in the furniture industry or for many other decorative applications by coating them with transparent PU systems using the RIM process. While the STREAMLINE machine system can only fully bring its strengths to bear with one transparent or coloured polyurethane system, COLOURLINE with MULTI-CONNECT technology enables fast and easy colour changes. Flexible production with multiple coloured polyurethane systems becomes possible through the system-related distribution of the isocyanate component and the polyol colour component in different units.
ELASTOLINE
- Low-pressure metering machines for processing cast elastomers
Cast elastomer products have excellent static and dynamic properties. When it comes to processing polyurethane-based casting systems and raw materials, the name ELASTOLINE has been a familiar term for high-quality end products for decades. Machines from the ELASTOLINE series reduce the amount of manual work required, improve hygiene in the workplace and convince through optimized functional sequences. The high-quality design of all assemblies ensures that these system benefits will persist in the long term, even if the production environment is harsh. The two different machine types Hennecke has on offer are tailor-made ELASTOLINE metering systems for MDI and TDI raw material systems (ELASTOLINE F) and NDI raw material systems (ELASTOLINE V).
HK-R 5000
- Low-pressure metering machine with high outputs for manufacturing high-grade slabstock foams
The HK-R 5000 is a metering machine whose components are perfectly suited to the requirements posed by the discontinuous production of open-cell polyurethane foam blocks. High-quality, thermoformable foam products are often used to manufacture roof linings in the automotive sector. A special stirrer mixhead and extremely powerful axial piston pumps enable outputs of up to 7500 cm³/s even if there is a great difference in viscosity. This allows large foam blocks of up to 6m³ to be made. The HK-R measures out liquid materials from amply-dimensioned work tanks. A plate heat exchanger replaces the shell and tube heat exchanger in the return line so as to control the temperature. It is installed in a separate, constant temperature control circuit with a dedicated pump that takes up much less space.
Mixheads
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KEY FACTOR FOR THE HIGH-QUALITY AND EFFICIENT PROCESSING OF POLYURETHANE
One key factor that ensures high-quality and efficient processing of polyurethane is mixhead technology. The development and manufacture of high-pressure mixheads requires a great deal of know-how and many years of experience. Hennecke has outstanding expertise in this area and makes its mixheads (apart from a few standard parts) in its own manufacturing halls. This is a novelty in the European competitive market. It is also the reason why many leading PU processors prefer mixheads from Hennecke. They know from experience that the high-quality design pays off in the production process.
MT mixheads
- High-efficiency deflection mixheads for very small to
very large outputs
MT mixheads are the most recent addition to Hennecke's mixhead portfolio, embodying a fundamentally new design which sets new standards in high-pressure polyurethane mixing technology. To the user, this innovation translates first of all into optimum processing results across the entire range of common PU systems. Our MT mixheads can inject up to six reaction components into the mixing chamber via high-efficiency injectors. From there the reaction mix flows into the 90° offset outlet pipe. This deflection supports the mixing process, calms the mixture and ensures a laminar, splash free discharge into the open mould. Due to their robust design, MT mixheads are also particularly maintenance-friendly and noted for their extremely attractive lifecycle costs. Moreover, they are optionally available with Hennecke constant pressure injectors which maintain an almost constant mixing pressure over a wide operating range. Output changes can thus be made without injector adjustment. At the same time, the application range of the mixhead is effectively expanded.
MN mixheads
- Groove-controlled linear mixheads for RIM
applications, filler processing and spraying
Our MN linear mixheads operate on the groove-control principle. Due to their special parameters, they are particularly suitable for polyurethane spray-moulding processes (PUR-CSM technology) and applications involving filled components. Hennecke's lineup of 2- to 4-component MN mixheads covers a vast spectrum of outputs, ranging from 6 cm³/s to 10,000 cm³/s. For CSM spray applications, users can optionally add 'smart' MN accessories such as a spraying lance for complex mould geometries or a high-performance cutter for a metered addition of glass fibres. Moreover, MN mixheads are ideal for attachment and thus suited for all RIM and RRIM processes. MN mixheads are optionally available with Hennecke constant pressure injectors which maintain a virtually constant mixing pressure over a wide operating range. Output changes can thus be effected without injector adjustment. At the same time, the application range of the mixhead is effectively expanded.
MX mixheads
- Piston-cleaned mixheads with double deflection
Apart from an excellent mixing quality and shot reproducibility, the MX type series allows for a very easy pressure control. The two or three-component mixheads are handheld or available as an add-on option. Typical uses are cold-curing flexible foam, rigid and semi-rigid integral skin foams as well as compact systems and filling foam. MX mixheads are also designed for pentane-blown systems. The double deflection of the flow makes groove-controlled recirculation mixheads particularly suitable for difficult-to-mix raw material systems. Moreover, MX mixheads are optionally available with Hennecke constant pressure injectors which maintain an almost constant mixing pressure over a wide operating range. Output changes can thus be made without injector adjustment. At the same time, the application range of the mixhead is effectively expanded.
MQ mixheads
- Piston-cleaned deflection mixheads with integrated
component separation
For decades, our MQ mixheads have gained a reputation for outstanding robustness and reliability, especially in processing components of low to ultra-low viscosity. Apart from their exceptional mixing quality, the integrated separation of reactive components gives the operator additional safety. Due to their ability to deactivate injectors individually, the 4- and 6-component versions enable a fast "shot-to-shot" selection of the formulation. MQ mixheads are mainly used for TDI systems or TDI blends.
MD mixheads
- High-pressure mixheads for continuous sandwich panel
applications
MD mixheads are operated on the impingement injection principle. Owing to their relatively small design dimensions and low mass, these dynamic mixheads are particularly well suited for use on oscillating filling manipulators. Their adaptability to various discharge systems enables MD mixheads to cover a broad range of applications. In CONTIMAT lines, the discharge system takes the form of a distribution rake to ensure a wide laminar application of perfectly conditioned material to the lower metal facing. Moreover, our MD mixheads are optionally available with Hennecke constant pressure injectors which maintain a virtually constant mixing pressure over a wide operating range. Output changes can thus be made without injector adjustment. At the same time, the application range of the mixhead is effectively expanded.
ML and MXL mixheads
- Air-cleaned high-pressure mixheads for various applications
Air-cleaned L-type ML and MXL deflection mixheads operate on the proven impingement injection principle. The entire recirculation of the components is groove-controlled. Due to the patented air cleaning capability based on the cyclone principle, the need for using solvents has been eliminated completely. When operated manually, the low weight of the ML and MXL mixheads enables ergonomic and less tiresome work even if moulds are difficult to access. With outputs of up to 9,000 cm³/s, these air-cleaned mixheads are also suitable for demanding tasks such as foam-insulating district heating pipes. Moreover, our ML and MXL mixheads are optionally available with Hennecke constant pressure injectors which maintain an almost constant mixing pressure over a wide operating range. Output changes can thus be made without injector adjustment. At the same time, the application range of the mixhead is effectively expanded.
MEL mixheads
- Stirrer mixheads
for elastomer applications
Right from the start, MEL mixheads are equipped with a hydraulic control of the mixhead injectors for extremely short and synchronous switching cycles. This is a novelty that guarantees the processor a superior metering quality. Moreover, MEL mixheads are also fitted with a sophisticated mixing chamber and stirrer geometry in hardened steel so that an excellent mix quality is guaranteed even when raw materials are difficult to mix. MEL mixheads are on offer for six or eight components. They are optionally available with Hennecke constant pressure injectors which maintain a virtually constant mixing pressure over a wide operating range. Output changes can thus be made without injector adjustment.
Stirrer mixhead for slabstock
- Dynamic stirrer mixer for slabstock applications
Slabstock stirrer mixheads combine injection and stirring principles and guarantee the user a laminar liquid laydown over the entire foaming width. Foam qualities with an extremely uniform pore structure that is free of pinholes and striation are achieved. The actual mixing unit is located centrally in the system’s foaming portal whereas the liquid laydown is discharged onto the bottom conveyor by a funnel that can be adjusted automatically or manually, depending on the system configuration.
Stirrer mixhead for HK-R 5000
- Stirrer mixheads for highest quality foams with
extreme outputs
HK-R stirrer mixheads are applied when extremely high-quality foam products for use in the automotive industry, or rather automotive interiors, are made. The highest amount of mixing energy possible is required to ensure a homogeneous cell structure. That’s why HK-R stirrer mixheads are equipped with a tailor-made mixing chamber and speed-controlled stirrers with a special geometry. Additional features such as adjustable mixing chamber pressure and a control-piston operated system for switching from recirculation to shot enable a laminar and absolutely bubble-free flow.
Slabstock lines
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Cost-efficient production of high-quality flexible foams
Slabstock foams are used when cushioning and insulating qualities combined with low weight are important. Processors who want to be competitive and conform to market requirements must be able to offer their customers high-quality products with a wide range of specific properties. Here, continuously as well as discontinuously operated slabstock systems technology from Hennecke offers the decisive advantage. The application of various technologies allows processors to achieve an extremely high degree of material yield. It is not without reason that Hennecke is the global market leader in this segment, offering a wide range of plant configurations for standard and special foams. In addition, we can also offer our customers slabstock systems technology that has been specially developed for test series and laboratory purposes.
MULTIFLEX
- Production lines for the continuous manufacture of
high-quality slabstock foams
Hennecke is considered the market leader in the field of slabstock machines and systems. This know-how is reflected in MULTIFLEX lines. When it comes to manufacturing slabstock in a continuous process, the use of high-pressure technology, the liquid laydown process and the flat-top system allows processors to achieve a highly efficient raw material yield and excellent foam qualities. As the MULTIFLEX is equipped with high-quality standard components, it can make the most of its advantages at an excellent price-performance ratio while reducing maintenance and spare parts costs. Its modular design is also consistently based on economic principles: Assembly and start-up times are reduced efficiently and for a long time after delivery, the plant can be retrofitted with additional modules, special accessories and equipment to meet new market conditions. This means that the production process will remain competitive in the long term.
QFM
- Production lines for the continuous manufacture of
high-quality polyether and polyester-based slabstock foams
The results of over 60 years of research and development are reflected in Hennecke’s QUADROFOAMAT (QFM) slabstock lines. Thanks to the fact that all components across all viscosity ranges are precisely metered, output settings are exactly reproducible, the adjustment range is large and because the plant has been combined with the extremely successful UBT technology including fall-plates, QFM lines open up many horizons for the efficient production of pinhole-free ether and esther foams that are up to 2,500 mm wide and, depending on the foam type and density, up to 1,500 mm high. A computer-controlled flow metering system provides additional production reliability, in particular when formulations or colours need to be changed on the fly without stopping the plant. Depending on foam type, formulation and plant configuration, cell sizes of 8-100 ppi are possible.
JFLEX
- Ultra-compact plants for the continuous production of
slabstock foams
So far, the market gap lying between discontinuous and continuous slabstock lines has not been covered yet. Hennecke is targeting at foam manufacturers who want to achieve a better quality and higher raw-material yield than with discontinuous plants but are unwilling to make the high investment in conventional continuous lines. With the JFLEX series, Hennecke has now launched a new slabstock line which also offers users with medium production volumes all the advantages of continuous production. The state-of-the-art production system is particularly impressive because of its extremely compact design and its excellent price-performance ratio. Of course, it comes with the usual Hennecke quality to the last detail.
BLOCFOAMAT
- Compact slabstock systems for discontinuous applications
Machines of the BLOCFOAMAT type have a track record of over 30 years in discontinuous slabstock production. When it comes to manufacturing rectangular and round blocks, BLOCFOAMAT users exert maximum influence on the quality and property of the foam, thus producing the high-grade basis of a great number of end products including mattresses or upholstered furniture. On top of this, the type series stands out for its efficient machine layout and attractive pricing. The current BLOCFOAMAT generation offers even more options and allows a wide range of polyether-based products to be made.
LABFOAM
- Slabstock systems technology for test series and laboratory purposes
The use of a LABFOAM laboratory plant quickly pays off - especially if you already produce slabstock products continuously. Even if LABFOAM systems operate discontinuously, their major area of application is about conducting test series for different raw materials and additive systems used in continuous slabstock production. Thanks to high-precision metering pumps, superior mixing technology and modern automisation, different test formulations as opposed to manual production can exactly be transposed to real production conditions. Thus you can judge the specific character and quality of a formulation without interrupting your current production or wasting a large amount of valuable raw materials in test series. There is also the option of equipping LABFOAM systems with patented NOVAFLEX equipment.
Sandwich panel lines
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Continuous and discontinuous production of metal composite elements and insulating boards
Rigid polyurethane foam has the lowest thermal conductivity of all insulating materials and is therefore used in the form of metal composite elements in industrial and cold store construction, as well as in cooling chambers for supermarkets and in thermal assemblies for trucks. With its highly-developed continuously or discontinuously operating sandwich panel lines, Hennecke has played a decisive role in this success story right from the start. With the company Hennecke Profiliertechnik GmbH, the Hennecke Group also has a highly-specialised supplier of high-performance trapezoidal sheet roll forming systems, which can be seamlessly incorporated into the existing plant concept of Hennecke's CONTIMAT continuous sandwich panel lines. In the continuous production of sandwich elements with metal facings, Hennecke is also one of only a few suppliers that can offer its customers convincing complete solutions from a single source.
CONTIMAT
- Continuous production of sandwich panels with rigid or
flexible facings
The CONTIMAT plant is designed for the continuous production of top-quality sandwich elements with different facings, panel thicknesses and profiles and - as an option - with a core structure made of polyurethane or mineral wool. With a usable width from 500 to 1200 millimetres, a panel thickness between 20 and 250 millimetres and a production capacity of up to 4000 square metres per hour, the advanced plant concept covers an extremely wide range of applications. On top of this, we offer you a great number of customized CONTIMAT technology solutions.
Highly efficient roll forming machines
- Systems technology for the
profiling of metal elements
With its CONTIMAT lines for the continuous production of high-quality sandwich composite elements, the Hennecke Group has made a name for itself in the global market. When the composite elements are provided with metal facings, Hennecke Profiliertechnik GmbH, which is based in the Siegerland region of Germany, offers suitable machine technology for surface and edge profiling. The newest member of the Hennecke Group has over 40 years of experience in building roll forming machinery. The portfolio of the highly specialised company includes amongst other things roll-forming machines and presses for manufacturing sectional shutter profiles and cut-to-length lines, as well as high-performance trapezoidal sheet roll forming systems. The latter fit perfectly into the existing plant concept for Hennecke's CONTIMAT continuous sandwich panel lines. In the field of sandwich elements with metal facings, the Hennecke Group is one of the few companies in the world that has extensive overall systems competence and is able to offer its customers complete solutions from sheet metal decoiler to packaging of the finished stack. Also when it comes to modernising and upgrading plants from other manufacturers, Hennecke Profiliertechnik GmbH is a competent partner.
PANELFOAMER
- Systems technology for the
discontinuous production of sandwich panels
PANELFOAMER production systems cover a wide range when it comes to the discontinuous manufacture of sandwich elements in terms of dimensions, facing and foam systems. To attain plane-parallel sandwich elements, heavy duty steel hydraulic presses are used. They are equipped with heated plate, rack and pinion guide system and special clamping cylinders. To prepare the reactive PU mix, PANELFOAMER systems use tried-and-tested TOPLINE high-pressure metering as well as mixheads that are either cleaned pneumatically (MXL) or with a piston (MT) and are moved by a special traversing rail system. Thus, big panels can also be foam-filled perfectly easily. The wide range of applications and the reliable systems technology of the PANELFOAMER have been developed in successful cooperation with the UK-based Hennecke agency AutoRIM Ltd.
Moulded foam lines
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MODULAR SYSTEMS FOR THE MANUFACTURE OF MOULDED FOAM PRODUCTS
More than 150,000 tonnes of PU raw materials are processed into moulded foam parts for cars per year using Hennecke's moulded foam systems technology. Apart from seats, head and backrests, there are many other applications in which the focus is on damping, insulation and the look and feel of a material. Hennecke provides its customers with efficient system concepts for all conceivable applications and the most diverse product ideas in all kinds of quantities. Regardless of the system concept you decide on, excellent mixing quality is standard with Hennecke thanks to the sophisticated mixhead technology and first-class metering pumps.
WKH SYSTEMS
- Flexible oval conveyor systems for varied products and large quantities
Hennecke's WKH oval conveyors use an oval transport system. The main area of application is the production of PU foam parts for car seating and head and backrests. Smaller parts as well as other products from different fields of application can also be made with the flexible WKH systems technology. Because processors are often confronted with the challenge of using different formulations for a whole range of products depending on the manufacturer and type of car and because the number of seating variations is increasing steadily, a mould change is often required. Hennecke’s oval conveyors are appropriate here especially because they have an automated in and outfeed station (QCD or ECD system) which enables the exchange of mould carriers during production and at a conveyor speed of up to 15 m/min.
Rotary tables (RTN/RTH)
- RTN/RTH systems
Rotary table systems for medium to large production quantities
Hennecke's rotary table systems comprise a circular horizontal conveying unit that accommodates the mould carriers. The technology is suitable for medium to large production volumes. The rotation of the table may be indexed or continuous, depending on process requirements. The cycle length is determined by the moulded part having the longest curing or handling time. Hennecke supplies rotary table systems in diverse circumferences. In line with customer needs, they can be combined with automatic filling manipulators, robots and/or electronic logging of production parameters for quality assurance.
Stationary production
- Modular systems for manufacturing moulded foam
products in small quantities as well as for laboratory use
When moulded foam products are made in a stationary process, the mould carrier stays in a fixed position. When several mould carriers are used, their assembly can be either linear or circular. Stationary moulded foam systems are mainly used when large-sized foaming moulds are involved or lower quantities are to be made, for pre-series or laboratory tests for example. Stationary systems are also ideal for applications with short curing times or different cycles. These latter determine the number of mould carriers used and also the optimum plant size within a series production.
Mould carriers
- Carrier systems for moulds
Hennecke mould carriers from the SM, SV, SVH and SSH series are central components of moulded foam lines. They are stationary or integrated into transport systems and serve to carry the foaming moulds. Mould carriers perform the closing and opening movements, absorb the process-related forces and turn the mould into a position that is ergonomic for users and handling equipment. The differences in the various carrier systems lie mainly in the opening and locking mechanisms.
Production lines for technical insulation
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AUTOMATED POLYURETHANE FOAMING LINES FOR REFRIGERATION APPLIANCES AND VARIOUS TECHNICAL INSULATION APPLICATIONS
In the manufacture of foaming lines for refrigerator cabinets and doors, Hennecke has made pioneering contributions to process and systems technology. For example, in the environmentally-compatible insulation of refrigeration appliances through the introduction of Pentane Process Technology (PPT). Today, Hennecke's refrigerator cabinet foaming lines and systems for the manufacture of insulated door elements ensure flexible implementation of a large part of the world's refrigerator production. Apart from meeting high environmental standards, the efficient systems also fulfil the strictest requirements regarding cost effectiveness, for example, due to highly efficient raw material utilisation and a comparatively low use of energy and space. Hennecke's many years of know-how in the area of refrigerator insulation guarantees the user reliable production and a faultless end product. Hennecke can also offer its customers sophisticated production systems and process technology for many other applications in the area of technical insulation using rigid polyurethane foam. These include production lines for the insulation of hot water boilers, water storage tanks and air handling units.
KGS
- Modular systems technology for effectively insulating
refrigerator cabinets
KGS systems technology is primarily used for the insulation of refrigerated appliance cabinets. A wide range of products can be made thanks to the flexible application possibilities and specific plant characteristics. This includes top-mount, bottom-mount or side-by-side equipment technology. KGS systems technology is consistently designed in a modular construction. This gives the processor a great deal of flexibility regarding the plant design and allows for quick and easy plant expansions. For this, the KGS system relies on stationary foaming fixture modules. Adapted to the individual requirements for the respective production, several KGS modules are coupled together. Typical applications include KGS5 or KGS10 configurations with five or ten foaming fixtures. With this, the modular construction shows its advantages in both small and large batches. In production lines with up to 40 foaming fixtures, Hennecke has already been able to reach production volumes of more than 6,000 cabinets a day, which is equivalent to a cycle time of nine seconds per cabinet. The production processes within the individual modules are identical, but in order to ensure high production flexibility they take place independently of one another.
ROTAMAT EF
- Highly automated and raw material-efficient production of insulated door elements
Tailored to meet your individual production requirements, ROTAMAT EF lines are equipped with five, six, seven or eight mould carrier places. When using highly reactive foam systems, quick rotational movement is necessary because the mould carrier is also closed by this operation. A suitably dimensioned toothed ring for achieving high acceleration rates allows the travel time to be reduced down to approx. three seconds in ROTAMAT EF systems. For a cycle time of 45 seconds, the EF type produces around 80 door sets per hour with eight mould carrier places. To ensure these cycle times and to enable as little maintenance as possible during operation, the locking and unlocking of the mould carriers and the opening rocker are now operated by an electric motor, as is the drum drive. The opening rocker is shaped in such a way that the closing movement of the mould carrier is largely horizontal. To reduce the operating costs, the ROTAMAT can be equipped with automatic door removal devices that move along the x-axis of the filling manipulator. The cured doors are picked up by vacuum suction cups after the mould carrier has been opened and conveyed to a depository next to the ROTAMAT. For very frequent mould changes, automatic mould change is also recommended. Pouring into the closed mould, for example when using low-boiling blowing agents, is also possible. Thanks to the use of Pentane Process Technology (PPT), the ROTAMAT not only meets economic requirements, but also lives up to the highest ecological standards.
ROTAMAT EM
- Efficient production of insulated door elements
ROTAMAT EM Polyurethane foaming lines enable the efficient production of insulated polyurethane door elements at an excellent price-performance ratio. The EM version is driven exclusively by low-noise and virtually maintenance-free electric motors. Among other things, a new design enables a direct drive of the drum for the first time. With the high acceleration of the electric drives, the ROTAMAT EM is also suitable for foam systems with a comparatively short reaction time. ROTAMAT EM systems are available for seven or eight mould carriers with external diameters of up to 2,500 mm in length, 900 mm in depth and 240 mm in height. The integrated mixhead manipulator can optionally be fitted in a biaxial variant or with two mixheads. The processing of Pentane-blown systems is also possible with the EM type. Among other things, the design includes integrated ventilation openings already mounted at the factory, which only have to be connected to an external exhaust air system.
KTT
- Automated production of insulated door elements with different curing times
The newly developed KTT foaming line for manufacturing insulated polyurethane door elements combines the advantages of a continuously operated circulation line with those of a stationary line. Disconnecting the operating line from the curing places enables improved operation of the line with varying curing times. The vertical arrangement of the curing places continues to permit a space-saving design of the line. The KTT system is divided into an operating and a curing section, and has an ergonomically optimized loading station as well as an automated foaming and removal station. In order to guarantee an optimum initial foam distribution of the door elements, two MT mixheads are used, which are guided by a multiaxial mixhead manipulator. The central element of the curing section forms a lifting/lowering gear, which transfers the foamed mould carriers into vertically arranged curing places. After the respective curing times, which may be different for each mould carrier, the mould carriers are supplied back to the operating section. The line also has a mould carrier changing station, which allows a mould carrier to be automatically moved in and out during operation.
SPRAY APPLICATION LINES
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HIGHLY EFFICIENT PRODUCTION CELLS AND PLANT DESIGN CONCEPTS FOR INNOVATIVE IDEAS IN POLYURETHANE SPRAY PROCESSING
The innovative and forward-looking PUR-CSM polyurethane spray-moulding technology has been successful in practical use for over fifteen years now, setting new standards in PU processing ever since whether in special-purpose applications or mass production. Among users, PUR-CSM has become synonymous with efficiency, flexibility and process reliability. Supplementing the engineering portfolio of advanced spray technology, customized mixheads have been developed along with various high-efficiency processing cells and machine designs. Together, these solutions provide suitable configurations for small and large production volumes and are tailored to fit the requirements of spray technology and its special parameters.
PUR-CSM PREG LINES
- Manufacture of lightweight composites with a
polyurethane matrix
The use of fibre-reinforced composites often starts when the properties of conventional materials no longer meet the customer's requirements. For the production of automotive load floors, for instance, lightweight composites with a polyurethane matrix completely meet the mark. The combination of materials allows for the positive characteristics of the individual components to be exploited while cancelling out unwanted features. End products thus benefit from high component strength and stability combined with low weight and complex geometries. With over 40 production lines installed and 90 % market coverage, CSM-Preg manufacturing cells make full use of their unique selling points in this area of application and are known for providing reliable production conditions that are perfectly suited for large volumes. As a generalist, Hennecke can supply everything along the process chain on a turnkey basis and tailored to individual production capacity requirements - from preform, robot technology, press and spray booth to safety technology.
PUR-CSM SANITARY LINES
- Reinforcement of bathtubs and shower trays
One forward-looking yet eco-friendly major application of PUR-CSM technology lies in the substitution of GFRP mouldings such as bathtubs and shower trays. Here, the use of PUR-CSM meets the most exacting demands in terms of production flexibility, reproducible part quality and material efficiency. For instance, CSM-reinforced bathtubs exhibit an outstanding thermal insulation and clearly reduced sound emissions. Moreover, the full elimination of solvents not only cuts production costs but also simplifies exhaust air system requirements substantially. CSM-Sanitary manufacturing cells are available in several designs and for various production capacities. Each line comes equipped with a TOPLINE high-pressure metering machine (a special version for sanitary applications) and state-of-the-art two-component spray mixheads. Multi-component systems and cutters for glass-fibre reinforcement are available optionally.
PUR-CSM SKIN LINES
- Production of PU spray skins for automotive and
non-automotive applications
The benefits of spray technology will pay off especially when it comes to finishing complex parts such as dashboards or door panels. A layer of aliphatic paint is initially applied by In-Mould Coating (IMC). This UV-resistant coating is then reinforced with a sprayed aromatic polyurethane. Compared to PVC, this combination exhibits greatly improved haptic properties and extremely low emission values. As the coating will only be applied where needed, up to 10% material savings can be achieved. Thus, spray skin is not only one of the most top-grade surface technologies, it is also very attractive in terms of cost. In addition, the user will achieve a reduced specific density at the same skin thickness. Hennecke supplies tailor-made systems technology for CSM-Spray-Skin applications. Depending on the design, these lines are fully suitable for large-scale production.
PUR-CSM LINES
- In the spraying process, PUR-CSM lines enable production of fibre-reinforced components or compound mouldings made of unfilled or filled PUR systems. As the basis and development platform for all known PUR-CSM products, the innovative systems technology offers exceptional competitive advantages compared to conventional processes and product approaches of this type. The modular principle of the PUR-CSM systems means that time and again, end products can be created with individual requirements in both an economical and efficient manner. In the process, users can individually adapt the PUR-CSM systems technology and even retrofit additional modules at any time. In the case of a product change or expansion, this is a decisive investment advantage over purchasing a new system. Many customers take full advantage of this modular system.