0 21 INNOVATIONS - hennecke.com · Allseas has already successfully realised 12 pipeline projects with Hennecke technology, including in the North Sea, the Atlantic, the Red Sea,

Journal for technologies and trends on the PU market

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INNOVATIONS210

Contents

Imprint :

Hennecke INNOVATIONS | 210

Published by:Hennecke GmbH, Sankt Augustin

Design and layout:REpublic, Linz am Rhein

Edited by:Torsten Spiller

Photos:Hennecke GmbH, Fotolia.deThe photos from fotolia.deare used within the frameworkof non-transferable sub-licenses.

Printed by:Printing office Engelhardt, Neunkirchen-Seelscheid

Total number of copies:5.000

Copyright:All rights reserved. No part of thispublication may be reproducedwithout prior written permissionof the publisher.No liability for mistakes.

Teamwork

under high

pressure

4

CSM hybrid

system for

Otto Bock

9

QFOAM is

gaining ground

13

CORIUM uses

PUR-CSM technology

15

Efficient air

conditioning

technology

thanks to

PU insulation

17

The Hennecke

ELASTOLINE-Days

7

11

Hennecke INNOVATIONS 210 2/3

Innovations

in slabstock

production

19

Open House at

MEG-MARUKA

in Japan

Trade fairs, seminars, conferencesand symposiums in whichHennecke will participate

FipurSao Paulo • 08.11. - 12.11.2010

InterplasticaMoscow • 25.01. - 28.01.2011

PU-Tech IndiaGreater Noida • 09.03. - 11.03.2011

JECParis • 29.03. - 31.03.2011

InterzumCologne • 25.05. - 28.05.2011

As at October 2010

Dear customers, dear readers,

Innovative production systems and processes alone are noguarantee of competitive advantage. What really counts areinnovation and unique selling points in the end product.So one thing we never forget during the constant furtherdevelopment of our products is the consistent optimizationof your portfolio. Thus, for over six decades now, we have beenoffering you first-class machine and plant technology forhigh-quality polyurethane processing with competitiveproduction results. To assist you in your investment decisionswe put our technical competence at your disposal alreadyin advance and with different raw material suppliers,if necessary.

In the current edition of INNOVATIONS, you can read abouthow satisfied our customers are with this strategy in termsof process development or close-to-production raw materialtesting for example. In our labs we tap new areas ofapplication and advanced uses together with our customers,whether they are start-ups (see page 15) or traditionalcompanies with longstanding experience (see page 9).

We will present many of these innovative products to youat the “K” in Düsseldorf – the world’s most important trade fairfor plastic processing. They will include a pipe section from thebig Nord Stream pipeline project (see page 4) and effectivelyinsulated air handling units that meet the highest demands(see page 17). I cordially invite you to Hennecke’s standwhere we will be able to introduce you to more innovationsand technologies and be pleased to demonstrate how wecan together transform your ideas for PU-based productsinto reality.

Alois SchmidManaging Director Technology

Edi tor ia l

2 Imprint

Fairs / Events

Nord Stream Pipeline4 - 6 Teamwork under high pressure

ELASTOLINE-Days 20107 - 8 Flexible plant technology

at the Hennecke ELASTOLINE Days

PUR-CSM9 - 10 Efficiency in combination –

a CSM hybrid system for Otto Bock

Slabstock foam11 - 12 Hennecke remains true to itself –

innovations in slabstock production

QFOAM13 - 14 QFOAM is gaining ground –

successful market launch

PUR-CSM15 - 16 More than skin-deep –

CORIUM uses PUR-CSM technologyfor homogeneous polyurethane products

Technical Insulation17 - 18 Efficient air conditioning technology

thanks to PU insulation

Hennecke-News19 Open House in Japan –

the 2nd "PU-Tech Days" at MEG-MARUKA

IN THIS ISSUE

When two high-performing companiescome together, the best results arealready in the making. And thisgoes for Hennecke GmbH and theAllseas Group S.A. The two firms havecooperated closely together anddeveloped a technology, which isproving itself day after day in thehardest of conditions.

We are talking about the Nord Streamproject – an offshore gas pipeline thatwill stretch from Portovaya Bay nearVyborg in Russia to the German Balticcoast near Greifswald. The Nord StreamPipeline consists of two 1,224-kilometrelong parallel pipes. This means that some200,000 pipes have to be welded andsome 200,000 weld joints have to besheathed.

Hennecke INNOVATIONS 210 4/5

August. Polyurethane from one of themajor raw materials suppliers as wellas Hennecke technology in the formof two TOPLINE HKs 1400/1400 with tankfarm control are also on board. In thepast, the Solitaire has already brokenseveral pipelay records in terms of layingspeed and depth.

The open-cell PU rigid foam Elastopor His the right tool for the job. It is a productthat a leading raw materials supplierhas further developed and optimisedin the past two years with regards tosolidity and processing speed.

The Nord Stream Pipeline will joinRussia and the European Union directlyvia the Baltic Sea and will transportup to 55 billion cubic metres of naturalgas to companies and private individuals.The first pipe is due to start operatingin 2011 and the second in 2012.The laying work is already underwayat full speed. In April this year,Saipem S.p.A.’s “Castoro Sei” was setto sea to begin the construction of thepipelines and Allseas' “Solitaire” pipelaying vessel has been hard at it since

Teamwork under high pressure

Nord Stream Pipel ine

"Solitaire" pipe laying vessel in action in the North Sea

Special technology forspecial applications

The optimised Elastopor H was developedover the past two years. The PU systemsused consist of two liquid components,which are pressurised by Henneckehigh-pressure foaming machines onthe “Solitaire” itself and mixed by theMT 26 mixhead before being used tofill the hollow space in the fitting.The MT 26 is a new mixhead that hasbeen especially designed for rigid foam.As an add-on mixhead it has an outputof between 1 and max. 3 kg/s. Moreoverit is equipped with constant pressurenozzles that allow the output to be variedwithout the pressure conditions changing.

Thanks to its good flow properties, thepolyurethane system is quickly anduniformly distributed throughout thehollow space. In order to prevent thepolyurethane rigid foam from beingbuoyant, it is configured to be open-celledso that hydrostatic pressure causesit to fill up completely with water.Its dimensional stability is crucial here.The material stands out with its highdensity of 160 kilograms per cubic metre,which maintains the exacting physicalproperties of this product. Thesecharacteristics are needed to protecthe weld joints from anchor and netdamages.

Hennecke and Allseas – a strong team

Founded in 1985, the Swiss-basedAllseas Group is one of the major offshorepipelay and subsea constructioncompanies in the world, operating sixspecialised vessels, which were designedin-house.

for this special application. Trace heatingwas fitted to the pipelines between themixheads and machines to preventthe pipes from freezing. The machineitself has been embedded in a containerto ensure that it operates independent ofthe ambient temperature. Dieter Müller,Hennecke’s Regional Sales Manager, saysthat “the whole solution was developedstep-by-step with the customer.The difficulty was that the machines,which are usually stationary had to movealong the pipes, with all the equipment.We solved the problem by putting themachines in containers with temperaturecontrol.” Hennecke is still in constantcontact with Allseas, adjusting themachines according to need. Henneckeemployees have been trained and continueto be trained for special work at sea.

At the last “K” trade fair Allseasapproached Hennecke with an enquiryabout a special machine that had tobe mobile so that it could be fitted ontoa ship. It also had to have an outputof over 3 kg/s and be suited to rawmaterials systems with mixing ratios of50 to 100 to 150. Moreover, it had to haveits own cooling circuit for ambienttemperatures of between minus 30 andplus 50 degrees Celsius.

At their meetings, the Hennecke andAllseas specialists decided that theHK 1400/1400, fitted with an MT 26mixhead, was the best solution. In orderto attain the necessary output thehigh-pressure foaming machine wasfitted with frequency converters. Processdata acquisition was also introduced

Also on board: TOPLINE 1400/1400, embedded in a special container

Nord Stream Pipel ine

Allseas has already successfully realised12 pipeline projects with Hennecketechnology, including in the North Sea,the Atlantic, the Red Sea, theMediterranean and in Argentina wherea pipeline was laid through the Straitof Magellan. The company has said itespecially values the reliability ofHennecke technology and the fact thatresults can easily be reproduced.Given the dimension of the Nord Streamproject, there has to be a high level ofconfidence between the executing andsupplying companies. Moreover, qualityand availability of the technology playa key role in ensuring that tight schedulesare met.

Safe and sound on the seabed

The Nord Stream pipe joints are each12 metres long and are made out ofan especially durable steel that isappropriate for underwater applications.They have a diameter of 48 inchesand are provided with a polyethylene anti-corrosion coating. The pipe is sheathedby a layer of steel-reinforced concretethat is between 60 and 110 mm thick.This sheathing protects the pipelinesfrom mechanical damage and preventsthe pipes from floating up becauseof their weight.

One shotevery 8 minutes

The steel pipes are automatically weldedduring the pipe-laying process. Shrinktubing is then pulled over the weld siteand the interruption of the concretesheathing is sealed with a sleeve.The hollow space that is formed is thenfilled with Elastopor H. Up to 45 (!) kgscan fit into such a fitting. Some 200,000fittings have to be filled, meaning thatHK machines are performing one shotevery 8 minutes, 24 hours a day and7 days a week until the pipe layingoperation is over.

Hennecke will presenta field joint (pipe with PU fitting)at the 2010 “K” Trade Fair.

Hennecke INNOVATIONS 210 6/7

Exibited at the K trade fair:Pipe joint with PU fitting

When it comes to processingpolyurethane-based cast systemsand raw materials, Hennecke GmbHhas been setting the standards forsix decades.Machines from the ELASTOLINE seriesare a familiar term for elastomerprocessors all over the world. On theoccasion of this year's ELASTOLINEDays at Hennecke's corporateheadquarters, interested processorsand representatives from the presswere informed about the benefits ofthe ELASTOLINE F. The completelynew type is the ideal partner forprocessing MDI and TDI systems.It is very attractive because of itsmodular machine concept whichis perfectly tailored to meet specificcustomer requirements.

Technical components made ofpolyurethane cast elastomers areindispensable in mechanical engineeringand many other industrial sectors today.Thanks to their extremely high

re-engineering, the machinesalways represent the state of the art inelastomer processing. The same appliesto the latest machine generation of theELASTOLINE series: the ELASTOLINE F.The machine supports the processor inthe production of MDI and TDI-basedPU elastomers of all types and ensurestop-quality production results evenwhen very different requirementsand extremely difficult processingparameters are to be met. The newmachine completely lives up to itsname affix „F“: Its machine concepthas a consistently flexible structureand thanks to its modular setup of themetering lines and its compact design,it offers enough room for customizedorder adjustments and subsequentmodifications. The tank sizes of up to320 liters are equally flexible. Proven hotair technology is used to control thecomponent temperature of tanks andpump unit. Thanks to the 60mm thickinsulation of the work tank cabins,considerable energy savings areachieved. Another highlight is theadvanced mixhead technology that is

resistance to wear,their great mechanicalresilience, their low residualdeformation and theirvibration-absorbing effect,there are many different applications.It's no surprise that the demand forPU-based cast elastomers has growncontinuously over the past few years.In order to optimize the manufacture ofelastomer parts in terms of quality andquantity, ELASTOLINE machines reducethe amount of manual work required,improve hygiene in the workplaceand convince through optimizedfunctional sequences. Based on long-standing experience and continuous

ELASTOLINE Days 2010

Flexible plant technologyat the Hennecke ELASTOLINE Days

Customer demonstration of the new ELASTOLINE F. From left to right: Jürgen Wirth(Manager, Application Technology), Matthias Klahr (Sales Manager Series Products& Head of Marketing)

Hennecke INNOVATIONS 210 8/9

equipped with a hydraulic control systemfor extremely short switching cyclesand superior metering quality rightfrom the factory. As a matter of fact,the construction and design of theforward-looking elastomer plant is ableto keep up with considerably more costlysolutions. The high-quality design of the

Nearly 100 visitors from the nationaland international elastomer processingenvironment attended the Days andobtained first-hand information aboutthe unique selling points of the newmachine generation. Among them werevarious cooperation partners from theraw material segment who took verygreat interest in the machine conceptof the ELASTOLINE F. On the whole,both event days were characterized byinteresting shop talk and discussionson specific projects. The HenneckeELASTOLINE Days 2010 were thus a verysuccessful event with positive feedbackfrom both the organizer and customers.

ELASTOLINE F is a Hennecke hallmark.It ensures an extremely long service life,even if the production environmentis harsh. The price-optimized setupand the corresponding sales strategywill certainly be of special interestto processors and potential customers.For processing NDI systems, thesuccessful ELASTOLINE V is still availableto Hennecke customers.

For the second time after 2007,the polyurethane specialists invitedelastomer processors and representativesfrom the press to the HenneckeELASTOLINE Days to inform them aboutthe special technical features andprocess benefits of the new machine.The focus of the two-day event thattook place on 15 and 16 June was onvarious papers and presentations and alive demonstration of the ELASTOLINE F.

ELASTOLINE Days 2010

Production of elastomer coupling systems (live demonstration). From left to right:Berthold Schimmelpfennig (Hennecke), Jens Geuer (Hennecke), Dr. Ralf Fritz(BASF), Christoph Evers (BASF)

ELASTOLINE mixheadwith hydraulic control

With its motto “Best in Foam”,Otto Bock Kunststoff GmbH underlinesits competence in manufacturingstate-of-the-art PU foams for allareas of application. According to theglobally-operating medium-sized firm,its constant principle is to spend onresearch and development and on newtechnologies. The decision to investin a modern and extremely flexibleCSM hybrid system for developing rawmaterials in spray skin and flexiblefoam applications certainly fits thegeneral picture.

and suppliers of PU-based plastics.It is no wonder, then, that the cooperationwith Hennecke goes back a long way.The machine manufacturer supplied oneof the first continuous slabstock linesfor producing ether and ester foamsshortly after it had been founded inthe 1950s. After 30 years of successfulproduction, the machine was replaced bya considerably larger “UBT” plant, whichin 2000 was supplemented with anotherstate-of-the-art slabstock line. Furtherinternational projects followed in the areaof continuous slabstock manufacture andthe production of polyurethane gel.

The two polyurethane specialists’most recent project is less aboutmanufacturing than about productresearch and further development.The aim is to find a way of manufacturingspray skins in a flawless and reproduciblemanner using various Otto Bockraw material systems. The traditionalcompany also wants to test and optimiseits in-house raw material systems inthe area of moulded foam applications.By using a tailor-made CSM hybridsystem, Hennecke can cope withthe different requirements in anextremely efficient way. The state-of-the-art laboratory plant is used in theon-site training center and has separatemetering lines for spray skin andmoulded foam applications, which canalso be utilised in combination forcertain processes.

A TOPLINE HK 650 with 60-litre worktanks is used for manufacturing flexiblefoams. Combined with the latest designof MT 18 mixheads, all common foamsystems can be processed without

To always conduct research into newpossibilities. That was and is Otto BockGroup’s key philosophy. It goes backto 1953 when the search was fora suitable material that could act asan alternative to the poplar wood usedin orthopaedic prosthetics. Dr Max Näder,Otto Bock’s son-in-law, recognisedthe vast potential of plastics and laidthe cornerstone for Otto Bock KunststoffGmbH. Today, the company is one ofthe most important technology partnersfor the renowned firm Otto BockHealthCare and for successful developers

Efficiency in combination –a CSM hybrid system for Otto Bock

PUR-CSM

"Ideal solution with a far-reaching range of applications" –CSM hybrid system at Otto Bock's technical lab

Hennecke INNOVATIONS 210 10/11

any difficulty. In conjunction with abig-sized industrial robot, the mixheadis mainly used on an automatic mouldcarrier that is similar in type and designto a Hennecke WKH system for producingcar seats. In this way, real productionconditions can be exactly simulated.Apart from the fully-automated operation

on the mould carrier, the metering linecan also be used manually and isavailable as a stand-alone system forcountless laboratory applications. Whenprocessing polyurethane spray skins, theobservance of all process parameters isas important for the application as themaintenance of a homogeneous surfacedistribution. The PUR-CSM metering linerelies on a MICROLINE 45 CSM meteringmachine that is equipped with typicallaboratory, small-volume tanks so that thecomponents can be switched rapidly.The metering line is ideally suited for theuse of different raw material systems,including high-viscosity components asare needed for the production of tear-resistant and heavy-duty spray skins.The MICROLINE also has a specially-fitted temperature control system for highprocessing temperatures. The MN6 CSMmixhead, equipped with a spray lance anda suitable industrial robot, ensuresthe optimal mixing of components andinjection into the mould. An automatedturntable rounds off the design, allowingthe mould to be positioned correctly.

The turntable has a further function:Thanks to the possibility of switchingpositions between the injection robots,the device is literally the pivotal elementof the flexible foam and spray skin line.Thus, the laboratory plant can be usedto produce back-foamed spray skins,for example. This offers the user realadded value, as the Technical Directorof Otto Bock Kunststoff GmbH, Dr MarcHerrmann confirms: “The multifunctionalCSM technology convinced us right inHennecke’s spray center. For Otto Bock,the new laboratory plant is an idealsolution with a far-reaching range ofapplications.“ Those responsible atHennecke are also convinced by the CSMsystem’s hybrid design, as Jens Winiarz,the Sales Manager in charge, says:“It is clear that Hennecke is in a positionto offer tailor-made laboratory systemsfor developing demanding and advancedraw material systems. A nice side effectis surely that a long story of trustingcooperation will be continued withsuccess.”

PUR-CSM

Spray skin expert: MN6 CSM mixhead with spray lance

Satisfied faces during the acceptance inspection. From left to right:Dr. Marc Hermann (Technical Director Otto Bock Kunststoff GmbH),Dr. Peter Gansen (CEO Otto Bock Kunststoff GmbH),Jens Winiarz (Sales Manager Hennecke)

For over six decades, Hennecke GmbHhas developed and produced high-quality polyurethane processingtechnology. It is considered themarket leader in the field of slabstockplants. But instead of resting on itslaurels, the company continues to putmore innovations on the market –such as a new screw-type stirrer anda flexible laydown system.

mathematically in order to developa new, flexible laydown system.

An interview with Karsten Brückner,Sales Manager Slabstock Plants

What function does the adjustablelaydown system fulfil?

Because of the special and flexible outletgeometry it is possible to distributecentrally-pouring reaction mixture with avery good age distribution onto foamingwidths of up to two metres at least.This is achieved because an adjustablegap between the upper and lower platessubjects the parts of mixture which flowforward to a significantly higher flowresistance than the amounts of mixturewhich flow to the side. And because thisrelationship can be adapted by thegap adjustment, the necessary flexibilityfor different formulations is achieved.On top of this, the modular design withits easily exchangeable upper and lowerplates allows for even more flexibilityregarding the different processparameters.

New stirrers for continuous slabstockplants MULTIFLEX, QFM and UBT

When slabstock is manufactured, stirrershave the task of mixing polyol,isocyanate and additives homogeneously.The mixer is also an important tool forcontrolling cell structure. Stirrer speedand mixing chamber pressure havea significant influence on cell size.However, the foamer has a dilemma:In conventional stirrer geometries, whenpin stirrers are involved for example,the mixing chamber pressure changeswhen the stirrer speed is varied and thepressure rises with increasing speed.So the size of the cell is changed in twodirections: A higher speed allows the cellsize to shrink and the rising mixingchamber pressure increases it.

Because of its geometry, Hennecke’snew screw-type stirrer has a conveyingeffect on the mixture. Thus the speed isdecoupled from the mixing chamberpressure. The screw-type stirrer canespecially help reduce the pressure inunfavourable conditions.

The new screw-type stirrer provides thefoamer with an additional influencingparameter on the size of the cell,opening up new degrees of freedom incell control.

Flexible laydown system for esterand special foams

Ester foamers generally face the taskof dispensing a uniform mixture with agood age distribution onto the conveyor.In practice, the mixer is operated in atraversing way or several different outletsystems are developed and used.Hennecke has simulated laydown flows

Hennecke remains true to itself –innovations in slabstock production

Slabstock plants

New laydown system with flexibleoutlet geometry

More freedom in cell control:new screw-type stirrer

What benefits do the customers have?

The adjustable laydown system meansthat an excellent age distribution can beachieved in continuous slabstock. Highlyviscous mixtures in particular can verywell be poured centrally and withouttraversing, and then distributed ontofoaming widths of up to two metres (andmore if necessary). This means that arelatively good shoulder structure witha striation-free cell structure can beachieved without a calibration device,which is especially advantageous forester foams that are often producedwithout a top paper. Moreover,transitions can be kept short whencolours and formulations are changed.

What is the most importantarea of application?

The most important field of use forthe flexible laydown system will initiallybe the flexible foam area for esterapplications. Foamers often work withseveral different self-made outlets.When it comes to foaming widths of over1.7 metres, pouring often takes place ina traversing way which almost alwaysleads to striation because reactionmixtures of different age flow into oneanother.

Have tests already been conductedunder production conditions?

Yes, field tests have shown that thefoaming widths reached so far can beextended. And in future it will be possibleto use a stationary mixer for many foamsthat have been produced in a traversingmanner up to now. Thanks to the highflexibility of the system, only onelaydown device will be required to cover

a wide rangeof very differentformulations. Andby adjusting thedistribution unit,formulations can bechanged more easilyduring a production run.

Who can use the adjustablelaydown system?

Operators of a Hennecke Ester UBT orQFM slabstock plant can attach thelaydown system to their mixer.

Mr. Brückner, thank you forthe interesting conversation.

Please contact Dept. Service Retrofit,Mr. Peter Bö[email protected],Tel. +49 2241 339-210with your enquiries about the screw-typestirrer or ester laydown system.

Hennecke INNOVATIONS 210 12/13

S labstock plants

Uniform age distributionover the entire width

QFOAM – the new generation ofextremely compact metering machinesbased on tried and tested Hennecketechnology – was launched on themarket over a year ago. This is reasonenough to take stock.

The brand QFOAM stands for a machinedesign that combines the advantagesof PU high-pressure technology withan impressive price-performance ratio.It is the ideal alternative to low-pressuresystems which require intensivecleaning. It comes in two sizes –the QFOAM and the QFOAM XL, whichhas more basic equipment anda significantly higher range of options.

We spoke toDave Swetang about his experiencesafter one year of production.

Mr Swetang, what is your experienceof QFOAM 720 so far?

The machine is running without anyproblem and the foam quality hasbecome much better. The high on-stream time, the reduced reject rate,the compact design and the user-friendliness all helped to impress eventhe operating staff. This coincides withour experience of Hennecke machinesin our Spanish factory.

What do you particularly likeabout the QFOAM?

The QFOAM has the versatility andflexibility of a Hennecke high-pressuremachine. The new mixhead is easyto handle and creates an excellentmix quality. And it is easier to fill cavitieswith foam thanks to the mixhead’slaminar output.

“Now that the QFOAM has been onthe market for over a year, we can takepositive stock,” says Matthias Klahr(Hennecke's Head of Sales for SeriesProducts and Head of Marketing).“We have already sold more than 40machines across the world. Oneimportant sales area is India, where wehave already delivered 6 machines fordifferent rigid and flexible foamapplications.”

The first QFOAM sold to India went toPromens (India) Pvt. Ltd, whose founderand CEO is Dave Swetang.

Promens operates worldwide andmanufactures a wide range of plasticproducts. The Indian subsidiary, withits 100 employees, uses QFOAM toproduce insulated plastic containersfor the cold chain in the food andpharmaceutical industries.

QFOAM

QFOAM is gaining ground –successful market launch

Hennecke INNOVATIONS 210 14/15

Can you tell us in just a sentence whatthe main advantage of QFOAM is?

QFOAM combines almost all thecharacteristics of high-end machinesand has an optimal price-performanceratio.

Could you give us a brief descriptionof your professional history?

I have a Master’s in process engineeringfrom the Technical University of Berlin.When I came back to India I foundedPromens (India) Pvt. Ltd – in 1996. I amnow the Vice President of the Societyof Asian Rotomolders Association.

Mr Swetang, thank youfor the interesting conversation.

Finally, it should be mentioned thatHennecke will continue to upgrade theQFOAM series. This means that allcustomer needs in the market segmentof standardised PU metering machineswill also be met in the future.

QFOAM

The QFOAM proves itself in harsh everyday production,on the left: Dave Swetang (CEO Promens India Pvt. Ltd.)

When it comes to manufacturingspray skins, PUR-CSM technologyfulfils the highest requirements interms of processing possibilities andspecific processing quality. Variousapplications in the field of water-resistant seating and other flexiblefoam parts as well as surfaces ofcomplex automotive interior trimcomponents testify to a multitude ofinnovative and practice-oriented uses.Word has reached beyond Europe nowthat the process stands for efficiency,reliability and continuous furtherdevelopment. CORIUM is the firstCanadian company to opt for PUR-CSMin the manufacture of high-qualityend products for the automotive andoutdoor industries.

CORIUM is of Latin origin and translatedliterally means “tough skin”. Anappropriate name for the Canadianstart-up company that has specializedin the manufacture of high-qualitypolyurethane-based surfaces since itwas founded in 2005. Apart from seatingfor all kinds of applications andcomponents for instrument panelsupports, CORIUM’s product range alsocomprises decorative elements formeeting high standards with regard tothe look and feel of products and theirdurability. Outside of the automotivesector, the company is now consideredone of the most important independentsuppliers of PUR parts on the whole NorthAmerican market. Its main businessarea is the substitution of productsthat until now were made with otherprocess technology.

The INNOVATIONS team spoke withCORIUM’s president and founder GeorgeMagirescu and executive vice-presidentPierre Maheux about German machinetechnology, business relations withHennecke and the advantages ofhomogeneous polyurethane products.

The spray skin experts justrecently won a National MarineManufacturers Association innovationaward in the “Furnishings and InteriorParts Category”. In spring 2010, CORIUMinvested in a PUR-CSM processing plantwith separate metering lines for sprayskins and moulded foam applications.The tailor-made production system offerssuperior product quality in spray skinapplications with and without directbackfoaming, and has all the USPsof CSM technology. For example, theshots can be interrupted at any timeduring the spray coating process.Depending on the application thiscan lead to material savings of over10 percent. Moreover, the system canalso process high-viscosity componentsfor particularly durable spray skinswithout any problem, doing credit to thecompany name.

PUR-CSM

More than skin-deep –CORIUM uses PUR-CSMtechnology for homogeneouspolyurethane products

Arrival of the MICROLINE in Canada: George Magirescu (President, CORIUM)and Pierre Maheux (Executive Vice-President, CORIUM)

Hennecke INNOVATIONS 210 16/17

INNOVATIONS:Since May of this year your productionhas put its trust in Hennecke. How didyou come across the Hennecke groupand what were the determining factorsfor your decision to invest in the Germanmachine and plant technology?

CORIUM: We first came across Henneckemachines at an American firm that isspecialized in the manufacture of PUfoam goods. So we have known aboutHennecke and its good reputation fordecades. But our decision in favorof the German company was not onlybased on its technological competence.The Hennecke team in Pittsburghconvinced us with its experience of themarket and wide-reaching knowledgeregarding PUR-CSM technology. On topof that, German machine and planttechnology also has a good reputationin Canada of course.

INNOVATIONS: Your company is thefirst in Canada to opt for CSM spraytechnology. How did you find out aboutthis technology and what are its mostimportant advantages in your opinion?

CORIUM: Spray skins became increasinglypopular in the top sector of the automotiveindustry towards the end of the 1990s.

were used. And this too is not onlyfor optical reasons. The environmentalimpact and the possibility of recyclingmaterials are becoming more and moreimportant to American manufacturers.

INNOVATIONS: What does the future holdfor CORIUM? Are you going to expandyour business? What role will PUR-CSMspray technology play?

CORIUM: We already have concrete plansto double our production capacity over thenext 18 months. We will be counting onpolyurethane spray skins and PUR-CSMtechnology to do so.

The Innovations team thanks the twofriendly Canadians for the interestingconversation. Hennecke wishes CORIUMfurther success with spray skins basedon PUR-CSM technology.

You can find out more about CORIUMby going to www.corium-ut.com.

It was immediately clear to usthat this technology would

solve all sorts of problemsin many areas – both for

the producers as well as forthe users. We don’t mean only

regarding look and feel but especiallythe functional optimization. Think aboutboat building for instance where certainneeds clash. For example water, UVand mold resistance as well as extremedurability for a long time. PUR-CSMenables us to manufacture a product,which is pleasing to the eye because theHennecke technology - in contrast totraditional production methods - givesus complete freedom regarding design.Moreover, it is considerably easier torecycle at the end of its life cycle thanksto the homogeneous PUR solution.

INNOVATIONS: Could you make suchproducts without PUR-CSM technology?

CORIUM: Traditional production methodscan’t keep up when it comes to designand specific surface texture unlessvarious manual processes are also used.But this would cause the manufacturingcosts to explode. The spray technologyalso offers the user other advantages.One single, automated process allowscolor or embossment to be chosenvery easily.

INNOVATIONS: What trends are youcurrently witnessing on the AmericanPU market?

CORIUM: There is a growing demand forspray skins, particularly in the Americanautomotive industry. Many models areopting for backfoamed spray skinsolutions, whereas before simple plastics

PUR-CSM

Homogeneous solution:spray skin seat cushion

with direct backfoaming

Hennecke recently completed a majorcapital equipment installation forTrane to produce residential airhandlers with Polyurethane foaminsulation. For over 100 years, Trane(part of Ingersoll Rand) has beena worldwide leader in the productionand sale of heating, ventilating,and air conditioning systems for bothresidential and commercial applications.Recently, Trane decided to introducea new line of air handling units(AHUs) for residential applications.The new “Hyperion”AHUs havemany innovative technologicaladvancements from earlier systems.One of these enhancements is inusing PU foam as an insulatingbarrier within the cabinets and doorsof the AHU.

zero “R” value once it is wet, whichoftentimes happens from “sweating”,leaks, during installation, etc.

- PU adds to the structural stability ofthe end product, whereas mineralwool does not.

In part due to these reasons, Tranedecided to switch from mineral wool toPU foam to increase the quality of theirAHUs. However, Trane was a newcomerto using PU foam insulation and neededa partner to work with them every stepof the way from design to full-scaleproduction. Hennecke became thatpartner of choice. Hennecke suppliedall the new capital equipment requiredfor the conversion to PU foam. Thisequipment included “wet” end equipmentand “dry” end equipment.

Historically, mineral wool has been theinsulation material used within AHUs.However, use of PU instead of mineralwool has several benefits:

- PU can be poured automatically intothe AHU, whereas mineral wool mustbe applied manually within the AHUs,which is both costly and a potentialsafety and health hazard (havingproduction employees working witha glass fiber product and workingwithin metal enclosures to applythat product)

- PU (due to its flowability) completelyseals the cabinet, increasingefficiency of the AHU

- PU maintains its insulation value(“R” value) through the life to the AHU,whereas mineral wool has virtually

Efficient air conditioning technologythanks to PU insulation

Technical Insulation

Continuous and space-saving: door production with the ROTAMAT KTR-8

Hennecke INNOVATIONS 210 18/19

The wet end equipment included bulkchemical storage systems as well aschemical metering systems. The dry endequipment included foam fixture devicesfor the cabinets (oval conveyors) andfor the doors (ROTAMAT).

Trane decided to utilize a two partpolyurethane foam. The poly side ispre-mixed with the blowing agentand all other additives. Both the polyblend and the iso are received in tankertruckloads. Hennecke supplied theunload skids, bulk chemical storagetanks, closed loop temperatureconditioning systems, chemical transferskids, and all controls for the bulksystem. Additionally, Henneckedesigned and installed the bulk system

For production of doors, Henneckesupplied two RotaMats to allow forclosed mold pouring of the preformeddoors. A ROTAMAT is a verticallyoperational foam fixture device thattakes up much less floor space thana typical turntable sized for the samepart capacity requirements. Each stationof the ROTAMAT can accept severalindividual door molds. As with the ovalconveyor lines, the ROTAMAT linesoperate automatically and continuously,with the only operator involvement beingthe loading of non-foamed doors andthe unloading of cured foam doors.Also as with the oval conveyor lines,Hennecke incorporated optical sensorsto ensure a door has been loaded intoa mold prior to foaming and RF tagsto determine which part is being foamedin order to automatically adjust meteringsystem parameters to the unique partrequirements. The mixhead is mountedon a linear actuator to position themixhead at the pour hole location ofeach of the doors prior to foaming.Changing of molds within the ROTAMATis extremely simple and fast via boltconnection with centering pin.

Hennecke utilized state-of-the-art AllenBradley controls for all the equipmentwithin the plant, with remote log-in andtroubleshooting and with data highwaycommunications to Trane’s internal plantproduction management system.

pipe loop to supply chemicals to allfour lines within the facility. Each lineincorporates a Hennecke TOPLINE HK270R metering system with MX mixheadto meter the foam into the cabinets anddoors. These metering systems includeday tanks with closed loop temperaturecontrol of the chemicals, meteringpumps with variable frequency drivesand magnetic couplings, flow meters,pressure and temperature sensors, andall the other high quality componentstypical of Hennecke metering equipment.

For production of cabinets, Henneckesupplied two oval conveyor lines. Theselines include universal foam fixturedevices with profile-specific toolingmounted in each fixture. The linesoperate automatically and continuously– the only operator involvement duringnormal production is manual loadingof non-foamed cabinets and manualunloading of foamed cabinets whichhave been cured by the time they reachthe unload area of the oval conveyor line.Hennecke utilizes optical sensors toensure a cabinet has been loaded into atool prior to foaming (to prevent pouringfoam into a fixture that does not containan actual cabinet). Hennecke alsoutilizes RF tags to determine whichpart is being foamed. This informationis used to automatically adjust themetering system parameters to ensurethe correct foam fill for each uniquesized cabinet. The mixhead is mountedon a robotic arm and line tracking isused to properly position the mixhead tothe pour hole of the cabinet as the lineruns continuously in order to completethe foam fill. The oval conveyor lineshave a convenient quick change loadand unload area for changing outcabinets in rapid fashion if necessary.

Technical Insulation

Efficient cabinet production:WKH oval conveyor

The Japanese machine manufacturerand polyurethane specialistMEG-MARUKA has long been a partnerof Hennecke GmbH. The twocompanies’ business cooperationin the field of technology and salesgoes back to 1982. Ever since, theyhave represented their commoninterests in Japan together, offeringtheir customers regional serviceall over the Asian continent. At anopen house event in Septemberthis year, they presented their jointsuccess in the form of innovationsand novelties to a wideaudience.

MEG-MARUKA andHennecke are not only

linked by a long alliance.Both companies enjoy an excellent

reputation within the polyurethane

Detailed and interesting presentationsgave the visitors an insight into variousnew products as well as pioneeringinnovations. Product specialists fromboth companies jointly presented theadvantages and USPs of their respectiveproduct portfolio. The main focus wason a WKH oval conveyor plant formanufacturing foamed seating, onthe additional units CARBOMAT andPENTAMAT and on several applicationsfrom sandwich panel production ina batch process. Between thepresentations, visitors were able tofind out more about the advantages ofQFOAM at live demonstrations, wheredifferent seat cushions were foamedusing a mixhead from the new MT series.

The success of the event has alreadybeen proven by many detailed inquiriesabout the products that were presented.One more reason to continue with theevent next year in close cooperation withMEG-MARUKA, and to make it a traditionwithin the partnership and cooperationof the two companies.

processing industry and have a vastpotential of technological competence.

This wasreason

enough topresent the

wide range ofmachine technology and

services at the “PU-Tech Days”that took place for a secondtime at the MEG-MARUKAplant near Nagoya (Japan)on the 7th and 8th ofSeptember. A year after an

extremely successful startof the event, customer interestwas even stronger. On bothdays, interested polyurethane

processors from all over Japanand Asia and representativesfrom the Japanese specialist

magazine “The Foam Times” cameto Nagoya to attend the product

presentations and live demonstrations.The first day was mainly directed atcustomers in flexible foam processing,whereas on the second day customerswere more interested in rigid foamapplications.

Open House in Japan -the 2nd "PU-Tech Days" at MEG-MARUKA

Hennecke-News

Long-time partners: the team of MEG-MARUKA and Hennecke GmbH

Live demonstration of the new MT type

www.hennecke.com

Innovationfor Retrofitting360˚ RETROFIT

Hennecke GmbH · Polyurethane Technology · Birlinghovener Str. 30 · D-53757 Sankt AugustinPhone: +49 2241/339-0 · Fax: +49 2241/339-204 · E-mail: [email protected]

>> For information about further attractive retrofit offers, please see www.hennecke.com/360

Our Aeromat control unit offers you innovative technology for simple, fast andsafe retrofitting. A user-friendly, forward-looking system with extendedfunctionality replaces the old control elements. Gone are the days of machinedowntimes because of unexpected repairs. At the same time, your productionwill benefit from practical advantages at a very attractive price-performanceratio:

The control system is 100% compatible with all Aeromat typesand years of construction.

Each control system is carefully examined and we guaranteethat it is delivered without faults. This ensures that thereare no wiring errors or malfunctions and the new systemcan be started up quickly without any problems.

• Intuitive and user-friendly - because the large full graphic touch screenand a completely new interface simplify the input of set pointsand machine parameters

• Fit for the future - because the SIEMENS PLC and all other componentsare state-of-the-art, meaning that spare parts will be availablefor a long time

• Reliable machine availability - because old control systems often cannotbe repaired and a replacement of the complete control system additionallyminimizes the risk of plant downtimes