Laminating Plants.

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1 Laminating Plants

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3 Short-cycle laminating plants: Siempelkamp applies pressure 3 Furniture products or laminate flooring: Laminated particle boards, MDF or HDF panels offer ambience and convenience for residential and business environments. Increasingly higher demands are put on product appearance and resilience and therefore also on the laminating technology. As a press specialist, Siempelkamp offers suitable concepts to refine these boards quickly, precisely and economically. In appearance and feel, the final products are hard to distinguish from genuine wood products, however, they are designed with better functional properties. Customers can choose from three different short-cycle press concepts which we tailored to the requirements of different customers, products and other basic conditions. Furthermore, we also supply the plant components around the press ranging from handling systems to storage technology to control technology all from a single source. Our recipe for success: turnkey laminating centers with three different short-cycle press concepts.

4 4 Siempelkamp press systems: the process leading to the perfect furniture and flooring panel! Siempelkamp plans and supplies complete laminating lines for the production of perfect furniture and flooring panels. The start-up and after-sales service are also included in our scope of supply. Our overview shows a typical line for the production of furniture panels and another one for laminate flooring Short-cycle press line with inline paper lay-up system 5 A typical line for laminate flooring 1 Raw board feed with distributor cart 2 Board separating station with suction feeder for quick stack changes without downtime 2 3 Precision paper lay-up system for back papers, raw boards, decorative papers and overlays with stationary 2-daylight magazines for quick pallet changes without downtime 4 Loader unit equipped with clamping devices, combined with vacuum unloading unit 5 Down-stroke press with oil-hydraulics and temperature control circuit 6 Equipment for the automatic press plate change 7 Edge trimming 8 Cooling line with quality evaluation 9 Stacking according to quality 10 Finished board removal and stacking 1 3

5 5 A typical line for furniture panels Raw board feed with distributor cart 2 Board separating station with alternating separation for quick stack changes without downtime 3 Paper lay-up station with inline paper lay-up and pallet changing unit 4 Loader unit equipped with clamping devices, combined with vacuum unloading unit 5 Down-stroke press with oil-hydraulics and temperature control circuit 6 Equipment for the automatic press plate change 7 Edge trimming 8 Cross-cutting saw with finished board cleaning 9 Optical inspection 10 Stacking according to quality 11 Finished board removal Short cycle press line with three paper lay-up systems 6 10

6 6 Standard, High-end, Eco: press program made to order A short-cycle press has to meet different requirements ranging from the simple furniture panel to the sophisticated special product. By offering a Standard Line, a High-end Line, and an Eco Line, we have tailored our press program to meet those needs! Standard Line: KT 400, versatile and tested The Siempelkamp multi-piston press has been setting benchmarks in the market since This press type is optimally suited for manufacturers wanting to produce a reliable product according to European standards. The outstanding features of the multi-piston press: + laminating of a wide-ranging board spectrum (thickness: 3 50 mm, width: infinitely from 1,830 to 2,100 mm, length: infinitely from 2,440 to 5,610 mm) + multi-piston design with up to 40 press cylinders arranged with increased density for optimal pressure distribution! + a press force of 400 N/cm² combined with the multi-piston principle allows the production of standard EIR (Embossed In Register) products + pressureless exposure time: 1.2 seconds + instead of the traditional rows of two cylinders, the cylinders are arranged in rows of three or more; optimal adjustment to each production situation with press cylinders that can be controlled individually + flexible size adjustment, adjustments take place automatically; in conjunction with pliant hot plates + specially designed lifting function of the loading system allows the controlled placement of the charge in the press, and thus prevents the charge from drifting! Three short-cycle press concepts: diversification through and through! Press KT 400: the workhorse KT 700: the new High-end Line Sophisticated concept: the Eco Line Made by Siempelkamp, proven and tested since 2000 Made by Siempelkamp, newly defined in 2011 Pressing pressure 400 N/cm² N/cm² 400 N/cm² Press cycles per hour Up to 150 Charging time/pressureless exposure 8 / 1.2 seconds 8 / 0.8 seconds 10 / 1.5 seconds time Optimally suited for customers manufacturing high-end products according to European standards... manufacturing sophisticated special products, for example, with deep embossing, metal decors, sensitive papers and special coloring Made by HAPCO with Siempelkamp components, since manufacturing simple furniture and flooring panels in an economical way and with Siempelkamp guarantee!

7 7 High-end Line: KT 700, the innovation According to the motto More pressure equals a higher profile Siempelkamp developed its multi-piston press concept into a new high-end model in The concept: The strong points of the Standard Line and several benefits for even higher press force and product quality. Thus, the KT 700 provides the best equipment for those wood-based panel manufacturers that want to offer products for a sophisticated living environment to their customers, for example, in the form of embossed tiles, wall or ceiling panels. The features: + new cylinder design in combination with revised arrangement of the cylinders inside the frame house, with considerably increased pressure up to 700 N/cm² + pressureless exposure time reduced to 0.8 seconds! + the innovative mounting of the upper hot plate results in precise parallelism of both hot plates + individual servo-controlled axes allow for active synchronization of the movement of the upper beam as well as a defined gentle touchdown on the product + quick changing system for the thermal decoupling of the cylinders + hydraulic tanks mounted left and right along the press allow for easy access to the cylinders from the top for maintenance reasons + production of sophisticated special laminates, for example, metal decors, deep dramatic 3-D embossings and products with special colorings + specially designed lifting function of the loading system allows the controlled placement of the charge in the press, and thus prevents the charge from drifting! Eco Line: smart and economical The third short-cycle press concept designed by Siempelkamp is tailored to the solid production of simple furniture and flooring panels: Siempelkamp builds this concept in cooperation with the Chinese machine and plant builder HAPCO. The result is the Eco Line, a performance-strong short-cycle press at a competitive price. The features: + manufactured by HAPCO on the basis of the proven multi-piston concept + key components supplied by Siempelkamp: inline paper lay-up system, hydraulics, control system, cylinders, and electronics as well as the service and warranty

8 8 Ultimate precision: short-cycle laminating plants with registered embossing system for tile products and synchronized pore structures When laminating high-quality products such as tiles and synchronized pore structures two properties are important: high precision when aligning the decorative papers and boards and repeat accuracy when placing the charges into the press. Both are achieved with Siempelkamp s registered embossing system for tile products and synchronized pore structures. Production flow The solution: With the help of reference marks, the charge is precisely aligned to the decorative paper and then placed into the press with a repeat accuracy of +/ 1 mm. Three cameras and adjustment systems per panel ensure that paper tolerances are compensated and that an optimum adjustment is achieved. 1 Assembly of decorative 2 papers and boards Camera-supported align of press charge Kamera- und Ausricht 1 Lay-up area Precise alignment of decorative papers and boards 2 Camera system and alignment unit High-precision alignment of charge

9 9 ment 3 Press process esystem 3 Press with loader and unloader systems Precise press table guidance Defined press plate alignment Accurate guidance units for the loader Toothbelt-driven loader/unloader with high performance and repeat accuracy

10 10 Handling and logistics: the extra to the press All three Siempelkamp short-cycle press concepts are part of a complete system ranging from the material handling to the storage and packing system. The advantage for our customers: All systems are from a single source and tailored specifically to customer requirements. Individual storage systems Siempelkamp s storage concepts are customized according to the product and general conditions and range from simple paper storage to air-conditioned high-bay storage units for sensitive papers. Raw board storage Decorative paper storage Inline and precision paper lay-up systems Two different concepts are available: The inline paper laying system separates the paper from two stacks automatically and includes a device for quick pallet changeovers. This system is designed for high outputs and is particularly suitable for the production of furniture panels. For the manufacture of laminate flooring Siempelkamp developed the precision paper lay-up system. This patented system features a high-precision paper laying and aligning device which achieves laying tolerances of +/ 1 mm in length and width! Inline and precision paper lay-up systems inside a laminating plant

11 11 Material handling Siempelkamp s material handling systems carry out the feeding of the boards from the board stack very reliably and as needed. Raw board feed Components downstream of the press After the press process and finished board removal, the star coolers, the board stacking and storing and the packaging and shipping processes ensure that the finished product reaches each remaining process step or use area with the same high quality it had after leaving the Siempelkamp short-cycle press! Stacking of finished boards

12 12 Intelligent electrical system and control technology: higher efficiency and improved quality Electrical system: focus on precision and cycle time With custom-made control technology, the electrical systems made by Siempelkamp ensure optimal functionality of the machine (press) and provide an accurate overview of the current condition, output, quality, and efficiency of the shortcycle press at any time. The start-up of the press takes place via a web-based interface within a very short time without a programming device. In this way, plug and play takes on a new dimension. The trending for diagnostics and product tracking are also fully integrated. To meet the demands of a performance-strong short-cycle press, a control was specially developed for the press based on a state-of-the-art SPS-based hardware of a well-known German control manufacturer. During the software development we focused on meeting the demands for precision and cycle time of the machine. The requirements for the interplay between the hydraulic system for the pressure and the position control are more than met. Thus, the product quality exceeds the requirements. Higher quantities and qualities View of the machine parameters

13 13 Intelligent product technology Input for production order change LAM-IQ is our process control system which is customized to the special demands of laminating wood-based boards. The integrated module structure meets exactly the needs of the operators. Advantages: + clear control over targets and objectives as well as decisive optimization approaches + quick and needs-oriented information more transparency and comparability of different locations, production lines and commissions + derivability of measures for efficiency increases if the comparison of two commissions provides different consumption data for the same product The downtime analysis provides production times and downtimes for the line at one glance. Avoidable downtimes are identified and their causes explored. Plant availability therefore significantly increases. Also included: automatic evaluations, for example, the shift report. Reports do not have to be created manually leading to a lower error rate. The manipulation of results is impossible. Quality protocol Data from the quality protocol provides possible causes for the production of lower qualities or scrap. LAM-IQ is available + as basic package + optional in the form of additional modules e.g., for order management (if needed with ERP connection to SAP, Baan, etc.) as well as for press plate and press pad management + as finish-installed complete package + including training of your personnel after start-up or upon agreement separately

14 14 All from a single source: the complete finishing line Around the short-cycle press of choice, Siempelkamp supplies complete finishing lines according to the all from a single source principle. Here, we also focus on providing our customers with systems that are precisely customized to their markets and general conditions. The more complete the greater the benefits: + optimal use of space + safe and gentle material transport + direct machine connections + high efficiency + ability to network the entire system from the process control to the production control level (ERP) + optimal integration of order and warehouse management as well as material flow control raw boards sanded boards decorative paper pallets laminated boards shipping Raw board storage 5 Short-cycle press Sanding line Cooling and stacking line 1 3 High-stack storage system 2

15 15 Cooling and stacking (see 1) High-stack storage system (see 2) Sanding line (see 3) Type KLS crane storage system (see 4) Raw board storage (see 5) Short-cycle press (see 6) Decorative paper storage with fully automatic loading system and turning device (see 7) Decorative paper storage Cut-to-size saw Packing line Buffer roller conveyor Type KLS crane storage system

16 Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG Siempelkamp CZ s. r. o. Hombak Maschinen- und Anlagenbau GmbH Siempelkamp Maschinenfabrik GmbH ATR Industrie-Elektronik GmbH Engineering Sicoplan N.V. Siempelkamp Logistics & Service GmbH Büttner Energie- und Trocknungstechnik GmbH Ventilatoren Apparatebau Siempelkamp (Wuxi) Machinery Manufacturing Co. Ltd., China CMC S.r.I. Machines & Handling W. Strothmann GmbH Sales companies/representatives Australia Siempelkamp Pty Ltd. Brazil Siempelkamp do Brasil Ltda. China Siempelkamp (Wuxi) Machinery Manufacturing Ltd., Beijing France Siempelkamp France Sarl India Siempelkamp India Pvt. Ltd. Russia Siempelkamp Moscow Singapore Siempelkamp Pte Ltd. Spain Siempelkamp Barcelona Turkey Siempelkamp Istanbul USA Siempelkamp L.P. All rights reserved. No part/parts of this publication may be reproduced, transmitted, edited or published in any form or by any means, electronic or mechanical, without the written permission from Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG. Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG Siempelkampstraße Krefeld Germany Tel.: +49 (0) 21 51/92-30 Fax: +49 (0) 21 51/