case study

Forming Line

The scope of delivery is a semiautomatic production line with the following characteristics: cutting of substrate blanks from roll including a semi-automated roll change system, blanket moulding and control system.

Overall description

  1. Preparing and cutting of substrate blanks from roll including a semi-automated roll change system
  2. Transferring of substrate blanks through the line
  3. Preheating of substrate blanks in the contact heating press
  4. Activating of glue layer on the decor blank in the infrared heating zone
  5. Transferring of decor and substrate blank into the moulding press
  6. Moulding of blanks in a moulding press (water-cooled tools with tensioning frames are necessary)
  7. Manually (due ejectors in the mould assisted) product unloading
  8. Easy mould change including quick coupling
  9. Electronic line control system
  10. EU conform work place safety and environment protection

60-90 s

  • SPS Simatic S7with MP
  • Simatic touch screen
  • Win CC (flex) visualizing

Blanks to be processed:

  • Width :  1300 – 1800mm
  • Length: 1800 – 3000mm
  • Automatic Forming Line – Current Configuration
    • Blank Size: 2800 x 1600 mm max
    • Decor + Substrate Only
  • Automatic Forming Line – Alternative Configuration
    • Blank Size: 2800 x 1800 mm max
    • Decor + Substrate + Heavy Layer

General Layout

1. Roll-off device

2. Positioning  table

3. Heating press 

4. Molding press

5. Mould change and Part unloading

6. Side feed decor

From Left to Right: 1. Roll-off device – 2. Positioning  table – 3. Heating press  – 4. Molding press – 5. Mould change and Part unloading – 6. Side feed decor

Process Flow

  • insert winding shafts stubs from each side, with pneumatic tension

  • edge control (working tolerance -+10mm) and material capacity control

  • pneumatic clamps on the puller bar, servo with drive

  • circle knife with pneumatic linear drive

  • material fixed by pneumatic brakes

  • Main line – substrate
    • linear shuttle between all line stations, linked and working in the same cycle stroke

    •  after heating the shuttle is equipped with pneumatic tension system to prevent shrinkage

  • Side feed – decor
    • linear shuttle with servo drive, blank transport  via pneumatic clamps on the puller bar

  • hydraulic lower & upper stroke opening  800 mm max 

  • closing force 30t

  • HMI controlled closing speed, 2 speed levels

  • 5 zones of IR heaters controlled by pyrometers

  • after the heating (face down) the decor blank is automatically transferred in to the molding press, turned face up and placed on the preheated substrate  

  • hydraulic 4 column press & upper stroke 1950mm max

  • closing force 100t

  • HMI controlled closing speed (3 speed levels)
  • the moulded product is ejected from the lower tool in the ergonomic height

Final Design