Maschinen- und Anlagenbau

Laminating plants

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Short-cycle lamination – a process for modern products with diverse applications

The lamination of particleboard,MDF, and HDF panels with thermo-set plastic film (resin-coatedpapers) is a fast, precise, andeconomical process which isused today for just about everyconceivable decorative surface.In fact, it would be hard to finda room anywhere in a buildingwhich does not have directlylaminated panels of some form,either in laminate flooring or furniture.

As a press specialist, Siempel-kamp has delivered the machin-ery to produce these productssince their first introduction andhas always worked closely withresin and paper producers toadvance the associated tech-nology. Today's modern short-cycle press offers exceptionalperformance to meet the increasing demand for laminatedwood-based panels.

With the precise technologyused in these machines, deco-rative films are pressed onto abase panel in such a way thatthe finished product is difficultto distinguish from genuinewood products. These laminatesare more durable and easier toclean than real wood and offera more attractive price (e. g.,laminate flooring). At the sametime, laminates help to protectour natural wood resources.

A lot of good arguments for agood product – one which is anongoing global success story.

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The press range for short-cycle laminating

Double Board PressThis press is based on the sametechnical concept as the SingleBoard Press, but designed to

laminate two boards simulta-neously with panel lengths of up to 2 x 5,600 mm.

Single Board PressThis press is the workhorse of the Siempelkamp productrange. Hundreds have beendelivered to customers whovalue its unbeatable reliability.This press features generouslysized hot platens of solid steelwhich provide excellent pres-sure distribution. The uniform temperature distribution of theseplatens is assured by use of adouble channel heating system.

The Single Board Press is alsofast, with charging times of 8 seconds and cycle times of up to 220 presses per hour.

Standard board sizes range from 1,830 x 3,660 to 2,100 x 5,600 mm.

Press with 2,200 x 5,700 mm hot platens

Press with two 2,200 x 5,700 mm hot platens

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Multi Power PressCompared to today's convention-al presses which have two rowsof pistons, a 2,600 x 5,800 mmformat Multi Power Press hasfour pistons across its width andten along its length (i. e. a totalof 40 press pistons).

The main advantage of this newdesign is a much more uniformtemperature and pressure distri-bution. This feature is a particularadvantage for the lamination ofHDF flooring and furniture panelswhich have greater width andlength variations. The MultiPower Press comes with severalpressure circuits which permitthe optimum adjustment oflengthwise and crosswise pres-sure for different board sizes.

This press is capable of up to220 presses per hour.

Standard board sizes range from1,220 x 2,440 to 2,440 x 5,700 mm.

Press with 2,600 x 5,800 mm hot platen

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Handling systems for speed and exact positioning

Other advantages:• No foundation pit• High flexibility due to

no-delay pallet change• Individual sheets of

paper can be turned• High output 8 sec. cycle

Precision paper laying systemSiempelkamp's precision paperlaying system was developedspecifically for the manufactureof laminate flooring. This patentedsystem features a high-precisionpaper laying and aligning devicewhich achieves placement tol-erances of +/-1 mm in bothlength and width dimensions.The paper is aligned using eitherthe edges of the paper or printmarks on the decorative paper.

Vacuum tables for aligning individual sheets of paper

Decorative paper laying station

Paper laying systemwith 3 laying unitsfor laminate flooring

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Inline paper laying systemThis production proven handlingsystem separates the paperfrom two stacks automaticallyand includes a device for thequick changeover of pallets. The decorative papers are runonto the carrier board symmet-

rically from above and below.Now covered on both sides, theboard is then conveyed to thetransfer station in front of thepress. Designed for high outputs, thissystem is particularly suitablefor the manufacture of furniture

panels and in combination witha high precision paper layingsystem for laminate flooring.

Inline paper laying system with pallet changing devices

To see all is to know allAll press lines utilize an integratedvisualization system based onIntouch Wonderware or Rock-

well RS View. The PLC controlsare from either Siemens or AllenBradley. This design enablesproduction and process data tobe acquired which, in conjunc-tion with an interface to a higherlevel operating system, form thebasis for managerial analyses.Additionally, the visualizationsystem also permits fast andreliable fault diagnosis.

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Short-cycle lamination line with register embossing for the production of laminate tiles and synchronpore products

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Production flow

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Press with loader/unloader

• precise press table guidance• defined press plate alignment • accurate loader guidance• toothbelt-driven loader/

unloader with high performance and repeat accuracy

AssemblyPress High-precision alignment

Camera-supported alignment

Camera systems and adjustment unit

• high-precision alignment

1 Paper and board assembling

• precise assembling of papers/foils and board

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High degree of consistentlay-up accuracyThe foils are laid up very accu-rately. In addition, the chargesare placed in the press very pre-cisely, cycle after cycle. Both arevital for obtaining high-qualityproducts.

The charge is aligned on thedecorative paper by means ofregister marks. This process isrepeated with a tolerance of +/-1 mm.

Compensating for paper tolerancesThree cameras and alignmentunits per board make it possibleto compensate for any papertolerances and obtain the opti-mal alignment.

Transfer station with camera monitoring upstream of the press

Short-cycle line with register embossing

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More profitability through intelligent MES and industrial IT

Lam-IQ – the intelligent process control-systemLam-IQ is a computer processcontrol-system by Siempelkamp,tailored to the special require-ments of wood products lamina-tors. Lam-IQ is based on a con-tinuous Software-Module struc-ture and can easily be tailored tothe individual requirements ofthe operating company.

The operating data enable atotal control over inputs and tar-gets. They deliver critical para-meters for making improve-ments.

The availability of fast and needs-based data leads to more trans-parency and makes it possibleto compare press line efficiencyin the same or different locations.

The comparison of two presslines results in different con-sumption data for the same product. In case of deviations,measures for an increase in efficiency may be derived.

The downtime analysis showsthe production and downtimetimes at a glance and aims atidentifying avoidable break-

Recording of quality data

downs and reducing the possiblecauses. By means of downtimestatistics, the analysis of thisdata is carried out in tables andgraphical presentations. Conse-quently, bottlenecks can berecognized clearly and can beeliminated. This leads to betterequipment availability.

Further analyses, for examplethe shift report, are generatedautomatically. In comparison to the manual reports, the auto-matic reports take considerablyless time to be generated, causefewer mistakes, and prevent themanipulation of results.

The examination of the data ofthe quality protocol indicates

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possible causes for minor qualityproblems or even scrap.

Besides the modules implemen-ted in the basic package, furthermodules as options for the ordermanagement (if required withERP-connection to SAP, Baan,

etc.) as well as press plate andpad administration are available.

The system will be supplied fullyinstalled as a complete package.The personnel will be traineddirectly after start-up or one byone by arrangement.

Quality report

Entry for production order change

Software Modules

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Siempelkamp engineers, supplies and commissions complete laminating plants –

using in-house production ex-pertise and process technology.

A typical plant for furniture panels●1 Raw board infeed with

distributor carriage

●2 Separating station with double transfer device for no-delay stack change

●3 Paper laying station with in-line paper laying system andpallet changing equipment

●4 Clamp-type loading devicecombined with vacuum unloader

●5 Down-stroke press with oil-hydraulics and temperaturecontrol circuit

●6 Automatic press caul changeequipment

Short-cycle press with inline laying

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A typical plant for laminate flooring ●1 Raw board infeed with

distributor carriage

●2 Separating station with raw-board suction carriage forno-delay stack change

●3 Precision paper laying unitsfor balance paper, laying onraw boards, decorative papersand overlays with permanentlyinstalled 2-deck magazinesfor no-delay pallet change

●4 Clamp-type loading device combined with vacuum unloader

●5 Down-stroke press with oil-

Siempelkamp short-cycle press lines for perfect furniture and flooring panels

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●7 Edge trimming equipment

●8 Cross-cut saw with finished

board cleaning device

●9 Quality-based stacking

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Short-cycle plant with 3 paper laying units

hydraulics and temperaturecontrol circuit

●6 Automatic press caul change equipment

●7 Edge trimming equipment

●8 Cooling section with qualitycontrol

●9 Cross-cut saw with finished

board cleaning device

●10 Quality-based stacking

●11 Finished board removal and pallet stacking infeed unit

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The complete laminating plant with integrated logistics

Paper pallets being forwardedfrom the warehouse

Finished board stacking store

RFZ high-rack storage system

Short-cycle plant

KLS crane storage system

Sanding line

Cooling and stackingequipment

Short-cycle plant

RBG high-rackstoragesystem

Paper pallet store

ContiRoll® press

Short-cycle press

Cooling and stacking equipment

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Siempelkamp is able to supplycomplete innovative systems. Incombination with SiempelkampHandling Systeme (SHS), Siempelkamp is able to buildcomplete laminating productioncenters.

The customer benefits from thesystem in many ways: optimaluse of space, reliable and protective transport of materials,integrated system interfaces,and high levels of efficiency. The complete system can benetworked, from the basic process level to the enterpriseresource management level(ERP).

The result is the optimal integration of order, warehouse, and materials management.

Packing line

SFG large stack storage

system

Packing line

Cut-to-size

Raw boards

Sanded boards

Laminated boards

Paper pallets

Dispatch

Ro

ller

conv

eyo

rb

uffe

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Satellite vehicle for transportingstacks of boards (fully automatic)

Cut-to-size

Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG Siempelkampstrasse 75 47803 Krefeld Germany Phone: +49 (0) 21 51/92-30 Fax: +49 (0) 21 51/92-56 04 www.siempelkamp.com

Machinery and Plants

Representatives

* Minority Shareholding

Siempelkamp Handling Systeme GmbH & Co. KG

Italy Siempelkamp S.r.I.

France Siempelkamp France SARL

Australia Siempelkamp Pty Ltd.

Singapore Siempelkamp Pte Ltd.

ChinaSiempelkamp (Tianjin) International Trade Ltd.

Brazil Siempelkamp do Brasil Ltda.

Russia Siempelkamp Moscow

Sicoplan N.V.

Zweigniederlassung Maschinen- und AnlagenbauGmbH & Co. KG

Büttner Gesellschaft für Trocknungs- und Umwelttechnik mbH

CMC S.r.I.

PAL S.r.I.

IMAL S.r.I.

Siempelkamp Pressen Systeme GmbH & Co. KG

Siempelkamp Maschinen- und Anlagenbau GmbH & Co. KG

Maschinen- und Anlagenbau

G. Siempelkamp GmbH & Co. KG

Engineering

Pressen Systeme

Industrieplanung

Handling Systeme

Siempelkamp L.P., Marietta, USA

Siempelkamp Canada, Cambridge/Ont.

Siempelkamp (Wuxi) Machinery Manufacturing Ltd.,China

Trocknungs- und Umwelttechnik

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ATR Industrie-Elektronik GmbH & Co. KG