'Budimpeks F' - equipment for sandwich panel production

1. BASIC AND OPTIONAL EQUIPMENT SPECIFICATION

BASIC EQUIPMENT

#	Title	Model	Quantity	Weight, kg	HWD, mm	Price, EUR
1	De-coiling barrel without actuator (weight of steel roll - up to 4t)	RBR-21.05	1	460	1400х1400х1250
2	Guiding device (board, tracker, cutting-to-length (across cutting) device (roller-type), rolling-on device for protective film covering)	SN-0.6-02	1	125	800х1550х1200
3	Steel forming machine with simple control panel for 2 types of profile (side locks type-10: wall and roof; steel forming - "Linear-80")	PR-125.10/03	1	1950	2050х1550х1350
4	Screw press, length - 6m	PSP-1000/6	2	1225	3000х1350х1500
5	Universal table for manual cutting out of grooves in polystyrene foam and mineral wool (for inserting into roof panels)	SRW-12.01	1	45	1000х800х1200

Total: *

additional EQUIPMEN (you can make it yourself using our documentation)

#	Title	Model	Quantity	Weight, kg	HWD, mm	Price, EUR
6	Measuring table	S-03A/2000	1	70	6000х1150х1100	-
7	Delivery table	S-03B/2000	1	40	6000х1150х1100	-
8	Table for glueing	-	3	40	1500х1150х1100	-
9	Platform for sandwich panel packing	-	1	120	9000х1100х250	-
10	Trolley platform, 3m	-	1	45	3000х1100х1000	-
11	Trolley platform, 6m	-	1	90	6000х1100х1000	-
12	Special tray, 3m	-	2	60	3000х1100х600	-
13	Special tray, 6m	-	2	120	6000х1100х600	-
14	Spacers	DP-03/2000	100	115	1000х980х20	-

Notice: real prices can differ from abovementioned. Please, write us to get an actual information.

2. INDUSTRIAL ALLOCATION SCHEME

1. Steel rolls
2. Glue
3. De-coiling barrel
4. Guiding device (+ measuring table)
5. Manual guillotine
6. Steel forming machine
7. Special guillotine
8. Delivery table (for already formed steel)
9. Trolley platform L=6 м (W-1/6)
10. Universal table for foam plastic and mineral wool cutting
11. Sandwich panels press
12. Pressure plates and spacers
     L=2,0 m - 40шт (DP) (spacers)
     L=1,0 m - 40 шт (DP)
     L=0,5 m - 20 шт (DP)
     L=0,25 m - 20 шт (DP)
     L=4,0 m - 4 шт (WP-1) (pressure plates)
     L=2,0 m - 6 шт (WP-2)
     L=1,0 m - 4 шт (WP-3)
     L=0,5 m - 5 шт (WP-4)
13. Special tray L=3 м (P-1/3)
14. Trolley platform L=3 м (W-1/3)
15. Platform for sandwich panel packing (P-2)
16. Special tray L=6 м (P-1/6)
17. Place for finished sandwich panels (stabilization process)
18. Store of mineral wool
19. Store of foam palstic

3. DESCRIPTION OF EQUIPMENT SET #1

General view.

EQUIPMENT installation Order
1. De-coiling barrel without actuator (weight of steel roll - up to 4t) RBR-21.02 Widsh of steel rolls up to 1250mm. Steel roll bore diameter - 600mm. Steel support roll is provided.

2. Guiding device SN-0.6-2. Structure: pressure roll, rubber-covered roller, across cutting device roller-type, guide (800mm) with clips, protective film covering device. Guiding device is provided for: 1) right orientation of steel film before measuring table, 2) covering of protective film on steel, 3) across cutting of steel with a glance of required size. Steel delivery is implemented by manual rotation of handle.

3. Measuring table. Steel film is delivered on it from guiding device. It is not supplied by the seller. Customer can make it himself using enclosed drawings. The length of measuring table should be equal to the maximal length of steel covers of sandwich panels. Guiding planks (length - 1800mm) for this table are supplied by the seller. Measuring table is designed for definition of the length of steel covers of sandwich panels and for right orientation of steel covers before steel forming machine.

4. Steel forming machine PR-100.4-02 for 2 types of side-locks (wall and roof type-10). Steel forming of main profile - "Linear-80". Steel forming machine has its oun control unit (with security elemints, signal lamps, control button "forward", "back"). The speed is constant - 5.5 meters per minute. PR-100.4-02 is a simplified type of steel forming machine PR-125.3/03.

5. Delivery table for finished steel covers of sandwich panels. A customer makes it by himself using enclosed drawings. Delivery table is equal to glueing table. The width of each table si 1500mm. For 6 meters-length panels 2 tables are required.

Near equipment (1,2,3,4) should be installed:
6. Table for cutting-out gooves SRW-12.01
7. Screw press PSP-1200/6.
8. Glueing table (3 sections by 1,5 meters)
9. Wooden trays..

4. SANDWICH PANEL PRODUCTION TECHNOLOGY ON EQUIPMENT SET #1

4.1 Wall sandwich panel production technology

Preparational operations - cutting-out of waves from foam plastic for roof panels and cutting-out of gooves in mineral wool. An operation takes 0.5 manhours per shift.
Equipment: universal table SRW-12.01 for foam plastic and mineral wool cutting.
Required staff: - 1 person.

Operation 1 - de-coiling of stell roll and cutting it to plates (with defined length)
Equipment :
-manual de-coiling barrel,
-guiding device with roll-type knives for across cutting of steel,
-measuring table with guide planks (length 1800mm).
Required staff: - 2 persons.

Operation 2 - Steel forming for sandwich panels
Equipment:
- guiding table (measuring table),
- steel forming machinePR-100.4-02,
- delivery table.
Required staff: - 2 persons (input of cutted steel into steel forming machine)
Operation 3 - tranfering of foarmed steel from delivery table to mezzanine or to wooden trays
Required staff: - 1 - 2 persons.
Operation 4 - glueing (transfering to glueing tables, manual glueing, moistening)
Equipment: - glueing table (3 sections by 1.5 meters with passages between them for steel plates transfering)
Required staff: - 2 - 3 persons.
Operation 5 - sandwich panl pressing (transfering of a lower steel panel from glueing table, foam plastic (or mineral wool) putting, transfering and putting of upper plate over foam plastic, stockpiling of stack of sandwich panels, tighten up of screws of press with force transducers).
Equipment: - press for sandwich panels L=6m
Required staff: - 2 - 3 persons.
Operation 6 - untwist of press and stocking of finished sandwich panels for "ripening"
Equipment: - screw press L=6m, wooden trays
Required staff: - 2 – 3 persons.

4.2 Roof sandwich panel production technology.

1. Operation 1, 2, 3 executed till stocking of the required quantity of upper roof steel plates of sandwich panels (mezzanine or to wooden trays).
2. Equipment revamping (changing of steel forming rolls) for forming of lower roof panels (estimated time is 20 minutes).
3. Operation 4, 5, 6 executed as in a case of wall panels production.

During stocking of aggregated sandwich panels on a press special spacers are used. You can learn more about a scheme of installation of pressure plate and spacers for pressing of wall and roof sandwich panels.

In the number of workers in the production sector is more then 5, operations 2,3,4, and 5 could be executed simultaneously (i.e. simultaneous operations of steel forming for lower roof plates and operations of transferring, glueing, preparing of workpieces for pressing and pressing of wall sandwich panels).

Depending on the required production plan the required staff may vary from 3 (all operations are executed in consecutive order) to 6 persons (all operations are executed in parallel order).
Estimated productivity of equipment set (with 3 persons of staff) is 50sq.meters of sandwich panels per shift. Monthly productivity is estimated as:
50 * 20 = 1000 sq.meters of sandwich panels per month (single-shift work)
50 * 20 * 2 = 2000 sq.meters of sandwich panels per month (double-shift work)

In a case work of 5-6 persons in production section a productivity can be doubled.
As the operation of steel forming is not a bottle-neck there is a big production reserves and a possibility of extension of press to 12 meters and more. There is a possibility of increase of productivity significantly!

Scheme of installation of pressure plates and spacers before pressing of sandwich panels in screw press.


1. Sceme of roof sandwich panel pressing (section)	2. Sceme of wall sandwich panel pressing (section)
1. Basing frame of screw press 2. Upper pressure plate 3. Stiffening rib 2. Lower pressure plate 5. Spacer DP-01/2001 6. Spacer DP-02/2001 7. Spacer DPD-(60,80,100,120,150)	1. Basing frame of screw press 2. Upper pressure plate 3. Stiffening rib 2. Lower pressure plate 5. Spacer DP-01/2001 6. Spacer DS-01/2001 7. Spacer DPS-(60,80,100,120,150)