In the modern construction industry, insulation and soundproofing materials are increasingly sought after, with PU (Polyurethane) Sandwich Panels being a top choice. Known for their superior thermal insulation, fire resistance, and ease of installation, PU Sandwich Panels are widely used in industrial buildings, warehouses, cleanrooms, and commercial structures. To meet this growing demand, Vietsteel, a leading machinery manufacturer in Vietnam since 1998, has developed the PU Sandwich Panel Line (Roof PU-RF) – a state-of-the-art, highly automated system that adheres to international standards. In this article, we will explore the details of this production line, including its technical specifications, operational process, and the benefits it brings to businesses.
Overview of the PU Sandwich Panel Line (Roof PU-RF)
Vietsteel’s PU Sandwich Panel Line (Roof PU-RF) is an advanced technological solution designed to produce PU Sandwich Panels for roofing and wall applications. With over 25 years of experience in machinery manufacturing, Vietsteel has integrated cutting-edge technologies into this product, ensuring high precision, stable performance, and aesthetic output. This production line is ideal for manufacturing PU panels that offer excellent thermal insulation, soundproofing, and fire resistance, suitable for a wide range of applications, including industrial facilities, cold storage, cleanrooms, and commercial buildings.
Key Technical Specifications PU Sandwich Panel Line
Based on the information from Vietsteel’s official website, the PU Sandwich Panel Line (Roof PU-RF) boasts the following key specifications:
- Motor Power: 121 kW
- Production Speed: 6–12 meters per minute
- Machine Dimensions: Length 68m, Width 4.0m, Height 2.8m
- Machine Weight: Approximately 60 tons
- Control System: PLC (Programmable Logic Controller) and HMI (Human Machine Interface) for automated, precise operation.
- Materials Used:
- Rollers: C45 alloy steel, CNC-machined, hard chrome-plated with a hardness of 45-48 HRC.
- Embossing Rollers: S48–52C steel, CNC-machined, heat-treated, and hard chrome-plated with a hardness of 50-55 HRC.
- Cutting Blades: SKD11 steel, CNC-machined, heat-treated to achieve a hardness of 55-60 HRC.
- Hydraulic System: Equipped with a cooling system, enabling continuous operation for 20–22 hours per day.
These specifications ensure stable, durable operation and the production of high-quality PU Sandwich Panels that meet stringent international standards.
Operational Process of the PU Sandwich Panel Line
The PU Sandwich Panel Line (Roof PU-RF) operates through a fully automated process, integrating multiple stages to produce complete PU Sandwich Panels. Below is a detailed description of each step in the production process:
Step 1: Steel Coil Loading (Un-coiler)
The process begins with loading steel coils into the Un-coiler system. This unit is designed with a hydraulic mandrel for automatic operation, ensuring a stable supply of steel coils to the production line. Vietsteel’s Un-coiler is optimized to allow coil replacement without stopping the machine, enhancing production efficiency.
Step 2: Steel Coil Forming (Roll Forming Unit)
Once loaded, the steel coil is fed into the Roll Forming Unit, where high-precision CNC-machined rollers made of C45 or S48–52C alloy steel shape the steel into predefined profiles for the panel. These rollers are hard chrome-plated to enhance durability and resist wear, ensuring a smooth and uniform panel surface.
Step 3: Polyurethane Foam Injection (PU Forming Unit)
At this stage, the PU Forming Unit injects polyurethane (PU) foam onto the surface of the formed steel sheet. The injection system includes nozzles, pumps, and tanks for PU chemicals, catalysts, and gases. The system is designed to distribute PU foam evenly, ensuring consistent thickness and quality of the insulation layer. Vietsteel uses environmentally friendly materials such as Pentane or HCFC-141b to enhance safety and environmental compliance.
Step 4: Panel Lamination (Laminating Unit)
After PU foam injection, the two steel sheets (top and bottom) are fed into the Laminating Unit, where they are pressed together with the PU core to form a complete sandwich panel. This process ensures high mechanical strength and optimal thermal and acoustic insulation properties.
Step 5: Panel Cutting (Panel Cutting Unit)
The laminated panel is then transferred to the Panel Cutting Unit, where CNC-machined SKD11 steel blades cut the panel to the specified length. The PLC and HMI control system allows precise length and quantity settings, with automatic alerts before order completion to ensure seamless production.
Step 6: Cooling (Cooling Conveyor Unit)
After cutting, the panels are moved to the Cooling Conveyor Unit to finalize the hardening of the PU core. This step ensures the panels achieve the required durability and stability before packaging.
Step 7: Automatic Stacking (Auto Stacking Unit)
The Auto Stacking Unit automatically stacks the finished panels according to the required quantity. Depending on the application (roof or wall), the system can perform cross-stacking to save space and facilitate transportation.
Step 8: Packaging (Panel Packing Unit)
Finally, the panels are wrapped with plastic film on four or six sides in the Panel Packing Unit. The system uses pallets to support easy transportation and storage, ensuring the panels reach customers in perfect condition.
Benefits of the PU Sandwich Panel Line (Roof PU-RF)
Using Vietsteel’s PU Sandwich Panel Line (Roof PU-RF) offers numerous advantages for businesses in the construction materials industry:
3.1. High Efficiency and Automation
The line is equipped with a PLC and HMI control system, enabling automated operation and minimizing human error. Production speeds of 6–12 meters per minute allow for high-volume output in a short time. The hydraulic system with cooling technology supports continuous operation for 20–22 hours per day, maximizing productivity.
3.2. High Precision and Quality
Rollers and cutting blades are CNC-machined for high precision and durability. The produced PU Sandwich Panels are uniform, aesthetically pleasing, and offer superior insulation and soundproofing (sound absorption >30 dB/m² at 50mm thickness).
3.3. Flexibility
The line can produce panels with lengths from 2m to 12m and core thicknesses from 50mm to 200mm, catering to diverse customer needs. The system allows easy configuration changes to produce different types of roof or wall panels.
3.4. Environmentally Friendly
Vietsteel uses eco-friendly PU materials like Pentane, reducing environmental impact and meeting international safety standards.
3.5. Professional Technical Support
Vietsteel provides 24/7 customer support, with a team of technicians available for installation, maintenance, and operator training. Genuine warranties and replacement parts from reputable brands like Siemens, Toshiba, Yuken, and Delta.
Applications of PU Sandwich Panels in Construction
PU Sandwich Panels produced by Vietsteel’s Roof PU-RF line have a wide range of applications in the construction industry, including:
Industrial Facilities and Warehouses: PU Sandwich Panels are used for roofing and walls, offering effective thermal insulation and fire resistance.
Cleanrooms: Their soundproofing and insulation properties make them ideal for cleanrooms in the medical and technology sectors.
Cold Storage: The low thermal conductivity of PU (0.023 W/m·K) ensures energy efficiency and stable temperature control.
Commercial Buildings: PU panels provide an aesthetic appearance, high durability, and resistance to harsh weather conditions.
Why Choose Vietsteel?
Vietsteel is one of Vietnam’s most trusted brands in construction machinery manufacturing. With over 23 years of experience, the company not only provides PU Sandwich Panel production lines but also offers comprehensive solutions for the construction industry, including roll-forming machines, purlin machines, and accessory-forming equipment. Here are key reasons to choose Vietsteel:
International Quality: Products meet CE standards and are exported to global markets.
Advanced Technology: Utilizes components from leading brands like Siemens, Toshiba, and Yuken.
After-Sales Service: 24/7 technical support, long-term warranties, and in-depth operator training.
Competitive Pricing: Vietsteel offers cost-effective solutions without compromising quality.
The PU Sandwich Panel Line (Roof PU-RF) from Vietsteel is an ideal solution for businesses looking to produce high-quality PU Sandwich Panels to meet the growing demands of the construction market. With automated technology, superior efficiency, and flexible production capabilities, this line not only optimizes the manufacturing process but also delivers long-term economic benefits. If you’re seeking a reliable PU panel production solution, contact Vietsteel via email at vietsteel@vietsteel.com or phone at (+84) 906 898 860 +1 571 267 9638 for detailed consultation.
Invest in Vietsteel’s PU Sandwich Panel Line (Roof PU-RF) today to elevate your production and meet the needs of the modern construction industry!