Foaming machines: precision and flexibility · 2018-05-10 · Case note Foaming machines: precision and flexibility COSMEC chose ABB as its exclusive motor and inverter supplier in

Case note

Foaming machines: precision and flexibility

COSMEC chose ABB as its exclusive motor and inverter supplier in order to build machines for the production of highest quality plastic material

COSMEC srl, based in Scandicci (Florence), is a company specialised in manufacturing foaming machines for the production of polyurethane foam (www.cosmec-pu.com). Since 1980, the company has contributed significantly with its design and construction skills to the advancement of processing technologies for these versatile polymers, developing innovative solutions in the field of mixing, dosing and process control.

A machine for every product needPolyurethanes are plastic materials obtained by mixing appropriately dosed organic liquid products (isocyanate and polyol). Foaming machines are divided into three categories: low pressure, high pressure and spray. Depending on the types used and the various components of the mixtures, it is possible to obtain rigid polyurethanes (sandwich panels, refrigerators, imitation wood, bearing structures), fl exible polyurethanes (cushions, mattresses), integral polyurethanes (car components, furniture) and elastomers (shoe soles, gaskets, tyres).

Modern moulding technologies and the growing need to operate in work environments free of harmful emissions require mainly the use of high pressure mixing machines that do not require washing with solvents. Nonetheless, particular applications - low pouring flow, low production volumes and mixing of specific products – still need low pressure machines. Furthermore, in recent years the spray technology, carried out individually or in combination with other processes, has opened up great potential for the manufacturing of new products, by solving construction problems and eliminating some difficult processing phasesof traditional production.

Precision and high reliabilityFor more than a decade, COSMEC has installed exclusively ABB low voltage motors and inverters in its foaming machines. The motors, which are various sizes, serve the pumps which control the dosing systems, the agitators and the hydraulic control units.

Foaming machines: precision and flexibility

Innovation and the right partners to stay competitiveIn addition to Italy, COSMEC operates directly in the Chinese,Vietnamese, Australian, Portuguese, Moroccan and Romanianmarkets. However, the machines designed and built in Scandicci are also sold to plant builders and therefore reach many other countries. Recently sales have been guided by the demand for rigid insulation polyurethanes, for example for refrigerator units, flexible foams for mattresses and cushions, and spray applications for ad hoc products.

The increase of exportations has helped to mitigate the decrease in local demand, but COSMEC’s true strategic response can be summarised in a concept: customisation. In fact, there is more and more focus on particular equipment able to best meet the specific needs of each customer, without neglecting maximum standardisation of the internal processes and components. Thanks to the flexibility of its organisational structure, COSMEC is able to follow each system from the design phase to installation and final commissioning at the customer’s site, also guaranteeing punctual post-sale service.

Operating in global markets and having to ensure increasingly fast response times, the choice of component suppliers with a globally well known and popular brand often proves to be a key success factor.

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The desire to standardise all the components related to motorisation and at the same time to ensure the highest possible level of reliability led to the choice of ABB as exclusive supplier. The first step concerned the dosing systems. In fact, the most important function carried out by the motors is the feedback on the pumps. Since the systems work with two, three or four different components, high accuracy is required in dosing. This can be achieved only thanks to the precision of flow capacity reading and, consequently, to the feedback provided by the motors associated with inverters, which vary the rotation values based on the needs of the various process phases. Dosage must take place correctly both in intermittent and continuous use and ABB inverter-motor systems always guarantee this.

The recent rapid development of inverter technology has allowed the processes to be optimised, significantly raising the overall levels of dosing systems reliability. The use of inverters also guarantees significant advantages where energy efficiency is concerned: on various occasions COSMEC has carried out on site behavioural surveys of machines under stress, comparing performance to that of old style machines and detecting energy savings up to 60-70%. In particular it is possible to maintain a very low motor rpm during the machine stand-by phase.

Once this solution had clearly demonstrated its validity “in the field”, the other motors, for the agitators and hydraulic control units, were also gradually standardised. On average, a new generation machine mounts five 2 to 6 pole ABB IE2 efficiency class motors rated from 0.18 kW up to 22 kW.