sponsoredRecycling Double-Belt Press Systems and Scattering Units: Flexible Combinations for High-end Products

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IPCO Germany GmbH Niederlassung Fellbach

When it comes to perfect surfaces and intelligent composites of boards and strips, IPCO’s systems are always a good choice. These systems also gain points from an ecological standpoint if they process recycled materials, bio-based materials, or other sustainable products.

The key to producing the ideal continuous panel product is the ThermoPress double-belt press system. Its adaptability is particularly noteworthy, as it is available with steel belts, PTFE belts, or a combination of both.

“We provide a variety of modular options and incorporate various processes, including polymerization, curing, and cooling, into the series to ensure that users receive a continuous production system that is customized to their needs,” explains Jens Gegner, Global Segment Manager Composites at IPCO. “Additionally, our systems are distinguished by their exceptional precision, which is enhanced by a thickness tolerance of 0.1 mm. They are also highly adaptive.” 

IPCO’s units also have flexible heating systems. The user can choose whether to use thermal oil, gas, or electrical heating. Whatever the case, the outcome is noteworthy. The products are characterized by their exceptional mechanical strength, defined thickness, and the absence of air inclusions.

Gallery

ThermoPress systems are capable of operating at temperatures as high as 400 °C and pressures ranging from 0.5 to 30 bar. Even though resins typically melt at 180 °C, speed is positively impacted by higher temperatures. “In this manner, we are able to reach a belt speed of 5 to 10 meters per minute,” Gegner says. Also, the temperature bar has been raised even more. “We are currently operating at 420 °C when pressing the anodes for dry batteries.” According to Gegner, this is a true borderline area and requires a high level of automation and rigorous monitoring of all process parameters, throughput, and final product quality. Only in this manner can the products produced satisfy the stringent quality standards of the automotive industry or battery and fuel cell manufacturing.

Precision Scattering Systems for a Variety of Materials

ScatterPro precision scattering systems and a comprehensive array of upstream and downstream equipment, such as feeding, unwinding/rewinding, trimming, cutting, and handling systems, can also be integrated into continuous production lines. These scattering systems are essential for the production of a variety of products, including flooring, composites, claddings, automotive and truck parts, hygiene products, electronics, filters, technical textiles, fiberglass, specialty carbon fibers, and more.

ScatterPro systems provide scattering solutions that are highly precise for a variety of materials, including recycled waste, granules, and powders. Scattering technology is particularly effective in ensuring a uniform distribution of materials and also makes a significant contribution to the circular economy. Not only can non-free-flowing materials, such as powders and granules, be incorporated, but also fibers and recycled material. Even powder materials that are sticky and employed in the production of battery electrodes can be processed. Gegner emphasizes that the product is distinctively distinguished by its consistent high quality, which is achieved through a very even distribution across its entire width. There are also different discharge systems that can be added depending on the type of recycled material.

The recycled material is fed into the hopper using vacuum suction or an auger system. Throughout the scattering process, the material is uniformly distributed within the hopper, and the fill level remains consistent. The scatter roller collects the material, which is then removed by a flexible doctor blade. The design of the doctor blade makes sure that the dose is the same across the whole scattering width. Sustainable production methods are supported by both the high level of automation and the unique design of the scatter roller.

Intelligent Reutilization

When using fibrous products, which are a common type of recycled materials, the ScatterPro FX model is best. “We have the capacity to integrate fibers that are 20 to 40 mm in length, with a bulk tolerance of ±6 percent. This is very accurate,” Gegner says. For instance, this is necessary for the reprocessing of rotor blades from wind turbines, which are required to be replaced every ten years but were previously incinerated or disposed of in landfills. However, these materials can be used again with IPCO systems.

The same principle refers to the waste generated by the utilization of glass mats. These are also frequently disposed of in landfills by users. But it is also possible to reprocess these fibers. “These recycled fibers, which come from glass fleece or rotor blades, are used to stabilize the middle layer of one of our products. The surfaces can still be made glossy or completely white,” Gegner says, adding another option. “There is significant potential for numerous natural fibers, including hemp.”

There is no doubt that the utilization of recycled materials will continue to rise, particularly in light of the numerous subsidies that are currently available to support the development of new applications. As an example, Gegner says, “We have already been able to produce innovative, sustainable building materials with our ThermoPress double-belt presses.” IPCO consistently collaborates with the customer to determine the optimal configuration for any future application that the coating and scattering systems are implemented. The company also provides systems for upstream and downstream processes, including the comprehensive planning and execution of heating and cooling systems and material feeding systems. With service technicians and technical specialists spread across 25 countries, IPCO clients enjoy round-the-clock assistance and quick turnaround times. This includes preventative maintenance like repairs and inspections done on-site.

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