Journal for technologies and trends on the PU market

www.hennecke.com

INNOVATIONS110

PUREOUTPUT

Imprint:

Hennecke INNOVATIONS | 110

Published by:Hennecke GmbH, Sankt Augustin

Design and layout:REpublic, Linz am Rhein

Edited by:Torsten Spiller

Photos:Hennecke GmbH, Fotolia.deThe photos from fotolia.deare used within the frameworkof non-transferable sub-licenses.

Printed by:Druckerei Engelhardt, Neunkirchen-Seelscheid

Total number of copies:5.000

Copyright:All rights reserved. No part of thispublication may be reproducedwithout prior written permissionof the publisher.No liability for mistakes.

Trade fairs, seminars, conferencesand symposiums in whichHennecke will participate

Hennecke ELASTOLINE-DaysSankt Augustin • 15. - 16.06.2010

ChileplasSantiago de Chile • 01. - 03.09.2010

Composite EuropeEssen • 14. - 16.09.2010

UTECH North AmericaHouston • 11. - 13.10.2010

Hennecke World Sales ConferenceSiegburg • 25. - 26.10.2010

K 2010Düsseldorf • 27.10. - 03.11.2010

As at May 2010

Slabstock

production at

Sheela-Foam

India

4

Award-winning

innovation

9

Agency in

Argentina

13

Pur(e) output:

the PUR-CSM

mixhead portfolio

14

360° RETROFIT

18

Pipe

insulation

7

11

Added Value

Extra Large

Contents

Hennecke INNOVATIONS 110 2/3

IN THIS ISSUE

Dear customers, dear readers,

Even those who set the standards cannot rest on their laurels.This awareness has been an integral part of our businessphilosophy for decades. It ensures that our customers andHennecke are right at the very peak of technology whenit comes to processing polyurethane. The current issue ofINNOVATIONS includes several examples of this.

We report on the consistent further development of PUR-CSMtechnology and the most comprehensive mixhead portfoliofor polyurethane spray applications in the world (see p. 14).Thanks to the customer-oriented 360° RETROFIT Service,Polyurethane processors also benefit from the consistentfurther development of Hennecke mixhead technology whenretrofitting it to existing production technology (see p. 18).New variations on tried-and-tested machine designs suchas ELASTOLINE F or the new QFOAM XL (see p. 11) prove thatwe always have the concrete needs of the market in focuswhen we explore our innovative potential.

On top of being innovative in machine and plant engineering,it also makes sense to put organizational processes tothe test. It is not without pride that we can announce thecomprehensive reorganization of our worldwide sales network:We have established new companies in Moscow (Russia),Mexico City (Mexico), Seoul (South Korea) and one branch inHyderabad (India). The establishment of a new agency in SouthAmerica (see p. 13) indicates that know-how and customerservice are also required in local regions. These efforts enableus to concentrate fully on a great number of different marketsand ensure that satisfied customers get optimum local service.You can find out how satisfied they are by reading about theIndian company Sheela Foam (see p. 4).

It is a great pleasure to invite you to read this new issueof INNOVATIONS and I look forward to entering a dialoguewith you.

Rolf TripplerManaging Director, Sales

Edi tor ia l

2 Imprint

Fairs / Events

QFM India4 - 6 Slabstock production at

Sheela-Foam India

Pipe insulation7 - 8 It’s all down to insulation

Durflex®

9 - 10 Award-winning innovation withHennecke machine technology

QFOAM XL11 - 12 Added Value Extra Large

Agency in Argentina13 Know-how and customer service on site –

new Hennecke agency in South America

PUR-CSM14 - 18 Pur(e) output:

the PUR-CSM mixhead portfolio

360˚ RETROFIT19 - 20 Uncompromising where customer benefit

is concerned - 360° RETROFIT

India is a country in transformationin many ways. The most-populateddemocracy of the world has a cultureand tradition that goes back formillennia. Thanks to the localknow-how in various, highly-modernkey industries, it also has anextremely promising future ahead.Ever since market liberalisationin 1991, the economy has grownrapidly and steadily. Today, India hasone of the world's most importanteconomies and reaches internationaltop levels in several fields. This isalso true for the Indian PU industry,especially for Sheela-Foam. By farthe most important manufacturerof PU foam goods in the South Asiannation, the company covers thegrowing domestic demand forhigh-quality slabstock using Henneckemachinery and plant technology.

Sheela-Foam has long been a knownname in the PU world. The internationalcompany was founded in 1972 by SheelaGautam and was pioneering in the Indian

Hennecke INNOVATIONS 110 4/5

applications. For these,Sheela-Foam usesmachinery and plants made byHennecke, the long-established PUmachinery supplier. By commissioninga QuadroFoamat (QFM) slabstock plant,it was able to recently establish thecontinuous manufacture of slabstockunder high pressure in its productionprocess.

The INNOVATIONS team spoke toTushaar Gautam, the grandson ofSheela-Foam`s founder and thecompany's current production manager,about the business relationship withHennecke, the company's experienceswith high-pressure machine technologyand the future of the Indian PU industry.

Mr. Gautam, you have been manufacturingPU foam products for 30 years already.And yet, the first Hennecke QFMslabstock plant only came on stream in2007.What were the reasons behind thisdecision?

PU industry. Today, the PU processor isespecially cherished for its wide anddiverse product range and it can lookback proudly on impressive growth.In India alone, Sheela-Foam has tenISO-certified manufacturing bases. Thereare five more bases on the Australiancontinent.Apart from high-quality standard foams,the company offers a variety oftechnical foams for special industrial

"We should have invested earlier inHennecke plant technology" –Slabstock production at Sheela-Foam India

QFM India

Tushaar Gautam (l), Rahul Gautam (r)

Today, the Indian PU market has reacheda stage where a great deal more quality

and anincreasinglyw i d e

p r o d u c trange aredemanded. This isonly possible withh igh-pressure

component mixing.By deciding to use Hennecke plant

technology in our production process wehave reacted successfully to the needs ofthe market.

Your first contact with Hennecke GmbHdates back to 1994. What can you sayabout your work with the German PUexperts to date?

I associate Hennecke with excellentcustomer service, before, during andafter an order is placed. What shouldespecially be mentioned is the overallservice and production assistance inthe initial start-up phase. Furthermore,Hennecke is always a reliable partnerwhen it comes to questions aboutthe processing technology in generaland system technology and controlin particular.

The QFM plant enables the continuousproduction of high-quality foam products.What has changed thanks to this in yourproduction process?

Apart from a remarkable plant reliabilitywe have observed a significant increasein production efficiency. Moreover, wehave the possibility to use all sortsof raw materials and therefore we cangradually expand our product range.Sheela is the first Indian company tooffer polyester-based foam products.Before, these always used to be imported.If anything, we regret not investing inHennecke plant technology earlier.

From left to right: KK.V.R. Prasad (Representative Hennecke India), Tushaar Gautam (Chief Operating Officer Sheela),Karsten Brückner (Sales Manager Hennecke), Arvind Kumar (Vice President Sheela), Rahul Gautam (Managing Director Sheela)

QFM India

What trends can you currently observeon the Indian PU market?

In the past, we have observed a growingdemand for complex and high-qualityfoams. I think that there is still a greatpotential here and we're well on the wayto tapping into it.

Despite the success of Sheela, the useof PU products is still quite low in Indiawhen one looks at the population figures.What more could be done to changethis?

Well, the excellent quality of our productsobviously offers the possibility toincrease the demand for polyurethane.

High-pressure technology also opensthe gate for many other appealingcharacteristics. Because of the effectiveexploitation of raw materials, theQFM system noticeably increases ourproduction efficiency. Furthermore, wehave to inform existing and futureconsumers more about the possibilitiesoffered by polyurethane. This way, wecan tap into new fields of application.The best example is the increasingnumber of technical foams that we nowoffer on the Indian market.

Thank you very much for the interestingtalk. We wish you and your companyfurther success in the future.

Continuous production of high-quality foams:QFM slabstock plant

Hennecke INNOVATIONS 110 6/7

Combined heat and power is the mottowhen it comes to the future of energygeneration. In order to save on rawmaterials and CO2, the waste heat thatoccurs when electricity is generatedwill no longer be able to escape unusedin cooling towers but will be utilized asdistrict heating or cooling. Insulatedpipes are necessary to make sure thatthe heating or cooling takes placewhere required. The demands placedon these so-called plastic-sheathedcomposite pipes in terms of insulationare steadily growing.Hennecke’s polyurethane high-pressure technology optimizes thepipes’ insulating properties andprovides the necessary high quality.

“For our insulated pipe system customers,one factor is definitely becoming moresignificant: energy loss over time,” saysKristian Overgaard, Technical Directorat Logstor in Denmark. “Therefore,the quality of the insulation is becomingincreasingly important.” Logstormanufactures pre-insulated systemsin 11 factories in seven countries. Apartfrom being used in district heatingtechnology, they are also deployed in onand offshore applications for transportingoil and gas products, in the processindustry as well as in shipbuilding.

Different manufacturing processes

There are four continuous productionlines comprising four TopLine meteringmachines with MX mixhead technologyand pentanization in online operationat the Danish Logstor factory formanufacturing these insulated pipes.There are also two special lines forproduction in a traditional discontinuousprocess.In the conventional process, pipes withfixed lengths are manufactured oneat a time. The medium pipe is equippedwith spacers and then fitted with ajacket pipe made of polyethylene.Then the PU foam is poured as rapidly aspossible into the cavity between theslightly tilted medium and jacket pipeswhere it subsequently expands from topto bottom. However, this production optionposes several problems and necessitatesthe right hardware in the form of state-of-the-art mixhead technology, as HenneckeSales Manager Dieter Müller explains:“To date, the process is the most commonbecause it requires the least investmentand is easily convertible and flexible.However, there can be turbulence duringPU injection leading to a formation of voidsand variations in density. It is decisiveto fill the pipe with as much reactionmixture as possible within a given time.

Part of the steam that is produced inheat and power cogeneration in a powerstation is used for heating purposes.There is a marginal drop in the degreeof efficiency in energy generation butthe total degree of efficiency increasesconsiderably. “The best combined heatand power plants in Denmark todayhave a total degree of efficiency of over90 percent. By comparison, manyconventional power stations in Europehave a utilization factor of between30 and 57 percent because residual heatis not used,” explains Overgaard, makingclear how much saving potential there is.The plastic-sheathed composite pipes thatare required in district heating networkscommonly exist in lengths of six, twelveor sixteen meters. They are made fromdifferent materials. The medium pipe canbe made out of steel, copper or plastic,whereas the thermal insulation is madeof foamed PU and the jacketed pipeconsists of PE. The medium pipe sticksout on both sides beyond the jacketso that the pipes can be joined togetheron the construction site. After themedium pipes have been connected,a PE fitting is positioned over the non-jacketed section and the cavity is filledwith foam.

It’s all down to insulation

Pipe insulat ion

High demands on insulation: plastic-sheathed composite pipes

Hennecke INNOVATIONS 109 8/9

Hennecke’s MXL mixhead is perfectlysuited for this and produces optimalresults.” Logstor still uses the classicalprocess for smaller batches because ofthe lower plant investment.

In the continuous version, the pipes arecut to the desired length after they havecooled down. To begin with, the innerpipes are fixed continuously and at thesame time, aluminized foil is preformedinto a U-shape. In a next step, a mixheadpours the reaction mixture onto the foil,

which is subsequently closed so that itenvelopes the inner pipe. Afterwards, thepipe, foil and rising foam pass througha calibrating unit for curing. The foam-insulated pipe is then put into an extruderwhere it is coated with polyethylene.The pipe is drawn uniformly during theentire manufacturing process, whichoffers one significant advantage,according to Dieter Müller: “The PUfoam just has to rise and doesn’t haveto overcome a flow distance as in thetraditional process. This means thatan extremely homogeneous densitydistribution and insulation is achieved.”

Higher market chanceswith high pressure

Using Hennecke’s high-pressuretechnology is doubly beneficial for Logstor.On the one hand, the company canfulfill the industry’s requirements for high-quality insulating properties and on theother, it can be sure of efficient andreliable production. An investment in thefuture, since the market for plastic-sheathed composite pipes will growconsiderably in the next few years, saysOvergaard. “All over the world, effortsto protect the environment are takingplace and we can also contribute tothe reduction of CO2 emissions with oursolutions. European governments and theEuropean Union have been promotingcombined heat and power systems foryears.We expect this to happen in EasternEurope and other parts of the world too.”

Higher mixing quality thanksto high-pressure technology

Besides the type of production, thereare significant differences when it comesto mixing the polyurethane componentspolyol and isocyanate. Usually, these aremixed in a low-pressure process withthe help of a dynamic stirrer. But becausedeposit accumulates in the stirrer inthe course of time, producers using thisprocess always have to wrestle witha reduction in mixing energy and a dropin the specific mixing quality as a result.Moreover, an uneven cell structure arisesbecause of the escape of pentane in themixing chamber. Further disadvantagesinclude trapped air caused by the stirrer,the fact that the mixhead has to becleaned with solvents after just a fewhours, and the impossibility of varyingthe output during a production run.With high-pressure technology, however,polyol and isocyanate are atomizedwith high energy according to theimpingement mixing principle. This leadsto a significantly improved mixingquality. Pentane can also be processedin a safer manner. “The PU foams havea very homogeneous cell structure.The cell sizes are smaller and moreuniformly spread than when low-pressuretechnology is used,” explains Müller.Overgaard adds: “The use of the systemsis much more comfortable: great outputvariability, additional components, suchas activators, can easily be metered, thereis less cleaning of the mixing chamber andno need for using solvents.“

Dieter Müller(Hennecke-Sales-Manager)

Pipe insulat ion

With its ballast bed partly foamed withDurflex®, Frenzel-Bau GmbH & Co. KGhas developed a real innovation in thefield of track bed systems.The technology that results from closecooperation between Hennecke GmbHand Bayer Material Science has nowbeen awarded by the “Germany – Landof Ideas” initiative.

Thanks to the additional option of mixingtime-critical components (online batchprocess), it was possible to optimally fitthe machine to the Bayflex® PU system.The results of the measurements andnumerous test series prove that thesystem lives up to its promise. There isa significant reduction of emissions aswell as operational and life-cycle costs.Repacking is not necessary and the

Durflex® is a system that effectivelyoptimizes track bed systems with regardto airborne noise, structure-borne noiseand stability. When using Durflex®, theballast body is fixed under a sleeper byinjecting a polyurethane (PU) system.In this way, hollow spaces can becompletely filled preventing the ballastmaterial from moving whenever trainscross the rails. This works in new railwayconstruction and renovation.

The potential of the new technology wasalready apparent during the first testseries in Hennecke’s technical lab.Already in the middle of 2007, a 300-meter-long pilot section was put intooperation in Uelzen (Lower Saxony) totest the knowledge acquired in real-lifeconditions. For this purpose, a specially-designed high-pressure meteringmachine of type TopLine HK650 wasinstalled in a train container. A tripledeviation Hennecke MX mixhead wasselected for injecting the metered mixture.

Award-winning innovation withHennecke machine technology –the Durflex® track bed system

Durf lex®

Solid and flexible at the same time:the Durflex® principle

The central part of the plant:TOPLINE HK high-pressure metering machine

May be out of date soon thanks to Durflex®:noise barriers along rail tracks

Hennecke INNOVATIONS 109 10/11

track’s service life is considerablyextended. Moreover, track deformation isavoided, thus reducing the number ofbroken sleepers and rails. Therefore, thenew technology further revolutionizesexisting track systems both in economicand ecological terms.

These many advantages were honouredwith a “Selected Landmark” award by the“Germany – Land of Ideas“ initiative andits patron, German President Horst Köhler.Hennecke congratulates Frenzel-Bau onthis special honour and is proud to havecontributed to the realization of suchpromising technology. In the long-

established company’s opinion, Durflex®

is an example not only of the wide rangeand applicability of polyurethane but alsoof the innovative force of Germanmedium-sized companies. Or, to put it inthe words used at the awards ceremony– “forward-looking, innovative, creativeand modern.”

Find more information about “Germany –Land of Ideas“ at www.land-der-ideen.de

Polyurethane injection into the track bed

Durflex® is a registered trademark of Bayer MaterialScience AG.

With the aim to ensure that there isan optimal solution and great practicaladvantage for each user andapplication, Hennecke GmbH hasdrawn on its vast experience last yearalready to develop a new generationof extremely compact meteringmachines based on Hennecke'swell-tested technology – the QFOAMseries. The machine and plantmanufacturer has now added the XLversion that stands out for itsconsiderably enhanced scope ofequipment even for specialapplications.

The fact that QFOAM metering machinesallow real added value to be achieved in

The name says it all: The XL versionprovides an extended basic configurationand compared to the standard type, itoffers polyurethane processors a muchgreater range of options - also and aboveall for special applications.

Clear and intuitive control system

As in the standard version of the QFOAM,the operator uses a Windows CE-basedoperator panel. The operating andmonitoring device has a fully graphics-capable display and allows easy andintuitive operation. On top of the panel, thewhole PLC automation is equipped withstate-of-the-art components that arehoused in an ergonomic operating system.

the production process has becomecommon knowledge about one year afterthe market launch. This is certainlybecause the major benefit of the QFOAMcan be explained in a few words:The machine concept combines theadvantages of polyurethane high-pressure technology with an extremelyconvincing price-performance ratio.Hennecke's comprehensive expertise andwell-known quality are aboard anywayand make the two-component machinesan ideal alternative to low-pressuresystems. Due to the positive customerfeedback and because Hennecke seesfurther potential in the market for seriesproducts in particular, the new QFOAM XLhas been added to the QFOAM series.

Added Value Extra Large -the New QFOAM XL

QFOAM XL

Tried-and-tested air-cleanedMXL mixhead

The machine concept of the QFOAM XLalso relies on the air-cleaned MXLmixhead and the tried-and-testedmetering technology of the TOPLINEseries. This combination enablespolyurethane processors to meter the PUcomponents precisely and achieve anexcellent mixing quality for a greatnumber of applications in the most variedareas. The MXL 14-2 mixhead functionsaccording to the impingement injectionprinciple. The whole recirculation of thecomponents is groove-controlled so thatthere is already well-conditioned materialat the beginning of a shot. In addition,the MXL for the QFOAM and QFOAM XLis equipped with Hennecke's patentedconstant pressure injector right fromthe factory. Thanks to the flow-optimizedinjector geometry, there is a significantincrease in production efficiency. Andbecause generally a lower operatingpressure is needed, there is less wearand noise development in the meteringpumps, and the energy consumption ofthe whole metering system is reduced.Themain applications of the hand-operatedmixhead are cold-curing flexible foam,compact systems, filling foam, integralskin foam, energy-absorbing foam and

for Hennecke, the QFOAM XL can veryeasily and rapidly be integrated intothe production process and moved, ifnecessary – even if the user is new to PU.The delivery times are also fast. Becauseof optimized production logistics, theQFOAM XL can already be on its wayto the customer about four weeks afteran order has been placed. From thismoment on, at the very latest, thecustomer will benefit from Hennecke'sexcellent service on everything that has todo with the new QFOAM XL.

rigid insulating foam. The high-techcomponent has a low weight because ofits efficient design. It therefore enablesergonomic operation and less tiresomework for the user even if moulds aredifficult to access. In addition, the aircleaning of the mixing chambercompletely eliminates the need forsolvents that are, for example, used forcleaning customary low-pressuremixheads.

Efficient machine concept with largerwork tanks

Compared to the standard QFOAM, themost outstanding feature are largerwork tanks in double-walled designand optional heating sleeves for ahomogeneous temperature control ofcomponents. Thanks to standard edgefilters and the option of retrofittingmagnetic couplings, the XL version ismuch easier to maintain. In addition, thereare useful features like the optional tankfarm connection, for instance. In spite oflarger work tanks and the extended baseframe, Hennecke has implemented thetypical QFOAM mobility also in the XLversion. Due to the compact design andplug-and-play installation that is typical

QFOAM and QFOAM XL control system Double-walled 250-l tank in the QFOAM XL

New MXL mixhead withconstant pressure injectors

Hennecke INNOVATIONS 109 12/13

Hennecke GmbH has established anew agency in South America in closecooperation with the Argentineanenterprise Jose Iturrospe S.A.I.C. Thefocus of the cooperation is on sellingthe Hennecke product portfolio and onqualified technical customer services.

Iturrospe, which is headquartered inRosario in the Argentinean Province ofSanta Fe, was established back in 1950and, as leading Argentinean manufacturerof hydraulic presses, has an excellentknowledge of the market and plentyof experience in the local mechanicalengineering sector. This makes thecompany with long-standing tradition anideal partner for the systematic expansionof the Hennecke sales and servicenetwork on the American continent.

According to information from theHennecke management, the new agencyis a response to the increasing potentialof the South American market andthe growing demand for high quality,polyurethane-based products withinthe region.

The experienced team of salesspecialists and technical expertswants to support the processorsof those products with a broadspectrum of services in the locallanguage. This also guarantees theshortest possible response timesfor delivery of plant and machinetechnology as well as spare parts.In addition, Hennecke and Iturrospewill also pool their know-how in termsof high quality hydraulic presses forthe discontinuous manufacture ofpolyurethane sandwich panels. Withinthe product group of sandwich elements,the sales area of the new agency coversthe whole South American land surfaceup to the state border of Panamaincluding Cuba.

Iturrospe will also offer all othercomponents of the Hennecke portfolio,except within the sales region of Brazil,where the long-term and competentHennecke partner RoWe will continue tohandle questions from local customersquickly and efficiently. Interestedcompanies can find more informationabout Iturrospe on the Internet atwww.iturrospe.com.ar.

Agency in Argent ina

Know-how and customer service on site –New Hennecke agency in South America

From left to right: Jorge Alonso (Sales Manager Iturrospe), Carlos Garcia (Ambassador - ExternalRelationship Ministry), Hector Iturrospe (Managing Director Iturrospe), Alois Schmid (Managing DirectorHennecke), Dieter Müller (Sales Manager Hennecke), Carlos Martese (Ambassador Coordinator -External Relationship Ministry) , Mariano Iturrospe (Managing Director Iturrospe).

Hennecke INNOVATIONS 109 14/15

Meanwhile, PU processors all over theworld are aware that PolyurethaneComposite Spray Moulding (PUR-CSM)uses spray technology to manufacturefiber-reinforced parts or compoundmoulded parts from filled or unfilledpolyurethane systems. However,thanks to constant furtherdevelopment and the modularexpansion of the product portfolio,new areas of application are alwaysbeing identified. One of the keyreasons for this is the use of state-of-the-art mixhead technology. At theJEC trade fair in Paris, Hennecke’scomposite experts are presenting twonew types in addition to their existingCSM mixheads, which makes theirpolyurethane spray technologymixhead portfolio the mostcomprehensive in the world.

Hennecke mixheads have an excellentreputation: They are used in existingsystems with over a million meteringsa day.

Inclusive of competitive uniqueselling points

The base material for the mixheadhousing is high-grade tool steel. In orderto ensure a flawless quality, the chemicalcomposition of the steel is checked anddocumented with a spectral analyzerbefore the production go-ahead is given.Then the blank is shaped into its finalform by various automatic lathes andmillers in the company’s own processingcenter. Up to 100 different mouldsare used in the process. In order toachieve the required and extremely highdimensional stability, state-of-the-artcomputer technology and a high degreeof intuition are needed. Intuition isensured by training employees for manyyears. These efforts guarantee the useroptimum production results and reliableplant technology, inclusive of competitiveUSPs. All CSM spray mixheads, forexample, benefit from the possibility ofbeing able to interrupt shots during sprayapplication. This has great customervalue because a uniform spray coatand reduced material consumption areachieved. Besides, the self-cleaningspraying injector that is typical of CSMtechnology means that minimum effort isrequired when it comes to maintenanceand cleaning. A positive side effect ofCSM technology is that there is no needfor using solvents at all. This does notonly reduce production costs but alsolessens the impact on the environment.It therefore makes sense to use CSMtechnology from both an ecological andeconomical point of view. Apart frommeeting the highest requirementsregarding flexibility in production,reproducible part quality and efficient

Ten years after it was invented, the fieldof application for CSM polyurethanespraying technology reaches far beyondthe automotive industry. The great varietyof use in the utility vehicle, sports andsanitary industries forms the basis ofperhaps the most advanced way ofprocessing polyurethane. The mainreason for this is close cooperationwith users as well as continuous researchand development in machine and planttechnology. Here, the mixheads areespecially important because theirmanufacture requires a high degree ofknow-how and experience. Henneckehas excellent expertise in this area andbuilds its mixheads, with the exception ofa few standard parts, in its own factories– a novelty in the European competitiveenvironment and a guarantee ofhigh-class economical polyurethaneprocessing. There is a reason why

Pur(e) output: the PUR-CSM mixhead portfolio

PUR-CSM

MN14 CSM with choppedglass fiber feed system

utilization of materials, CSM hardwarealso has another key advantage: themodular development and combinationpossibilities of different CSM productmodules. For instance, a customer candecide whether to install the choppedglass fiber feed system at the beginningor retrofit it later on. Customers canthus make targeted investments withouthaving to buy parts that are notrequired in the current process. Thisis more important today than ever before.

Best results when dealingwith high outputs – the MN14 CSM

The chopped glass fiber feed system ofthe newest member of the CSM mixheadfamily also has an adaptable modulardesign. But even without it, the MN14CSM has remarkable performancecharacteristics that are of specialadvantage to PU processors when itcomes to manufacturing large-sizedcomposite parts. The newcomer canprovide between 150 and up to 800impressive grams of reaction mix persecond, as required. With the choppedglass fiber feed system, the MN14 CSMenables a total system output of over1,000 grams per second – unique in thearea of polyurethane spray processing.The optional chopped glass fiber modulecan be activated separately. With itselectromotive drive and an output of upto 300 grams per second, it providesfor the necessary reinforcement in theend product.

Open for many applications –MN10 CSM and MN8 CSM

With outputs from 30 to 350 grams persecond, the MN10 CSM covers a verywide output range - even for up tofour raw material components. Onthe one hand, this multi-componenttechnology allows for the use of several

when the manufacture of composite partsis becoming more and more importantespecially because of the growingsignificance of lightweight construction,this is of great customer value.CSM semi-finished product processingand CSM chopped fiber technology canbe combined for instance. The additionalchopped fiber module needed for thiscan be used both as an importanttechnological tool in chopped fibertechnology for fiber reinforcement andas a useful and efficient supplementarymodule in semi-finished productprocessing for providing localreinforcement. For two-componentapplications that require a lower output,Hennecke customers can also takeadvantage of the MN8 CSM as from now.The MN10 CSM’s “little brother” has beenspecially designed for the output rangeof 20 to 150 grams per second, enablingan excellent mixing quality for systemsthat are difficult to mix.

PU formulations from the same rawmaterial family, which may differ in termsof reactivity, in order to serve mouldsof different sizes on one system. On theother, totally different PU systems andthus various manufacturing processescan be handled on one plant. At a time

A strong point of the MN10: honeycomb parts

MN10 CSM

Hennecke INNOVATIONS 109 16/17

Filler-capable for “toughest”application conditions – MN10F CSM

Systems that are difficult to mix alsoform the focus of attention when it comesto spraying filled PU systems.In addition to the suitable meteringmachine technology, a correspondingfiller-capable spray mixhead, the MN10FCSM, is available to meet the - in the true

sense of the word - “tough” conditionswhen filler is being used. Adding fillersto the media components such as heavyspar for reducing noise of parts invehicle interiors or calcium carbonatefor reducing exothermic reactiontemperatures – to name but twoconventional fillers – is an everydayapplication for this mixhead. The MN10FCSM combines the capability for solidswith a special injection technique insidethe mixing chamber. The so-called backflow mixing technology ensures optimummixing and therefore excellent productquality. But also when it comes toprocessing filled PU systems, Henneckedoes not rest at the classical two-component spray mixhead. Applicationsfor which a single heavy-layer structure

processing up to three base materialsright from the start. Moreover, the MN6CSM is also suitable for PUR systems thatare rather difficult to mix. Not only theoutput but also the design of the mixheadis quite minimalistic. With dimensionssimilar to those of a TV remote control,it is particularly suited for applicationswith difficult accessibility. In combinationwith a further new development, the MN6CSM is even appropriate for very narrowcomponent sections and highly-complexgeometrical shapes. A strongly modifiedspray injector in the form of a spray lancethat is just as thick as a finger and up to250 mm long is used for this. Moreover,because the spray lance does not onlyfunction as an extension of the sprayinjector but is also available with differentoutlet angles, the user can perform thespray application at different angles tothe mixhead axis. Equipped with a spraylance, the MN6 CSM truly lives up to itsnickname – internally the high-tech partis often described as the “hummingbird”.The spray lance is also available for theMN8 CSM and MN10 CSM mixheads.

Standard in the fieldof sandwich components

The sum of advantages makes CSMtechnology an indispensable partnerwhen it comes to polyurethane spraycoating. More and more users are

is not sufficient can rely on the four-component version of the MN10 F CSM.

Demanding in terms of quality,modest in terms of material:Polyurethane sprayed skins

For spray applications focusing on thinlayers or difficult access, outputs at thelower end of the high-pressure meteringapplication are important. The benefitsof CSM spray technology especially payoff when it comes to the surfaces ofcomplex components such as instrumentpanels or door trims. In the field ofcar interiors in particular, the most variedrequirements come together. Thedashboard of the new BMW 5 GT is anexample of such a complex application.Thanks to the soft touch effect, userscan achieve an excellent surface feel.However, PUR sprayed skin is not onlyone of the most high-class surfacetechnologies, it is also very attractivein terms of cost. Thanks to the optionto interrupt shots during the CSM sprayapplication, depending on the complexityof a part, there can be material savings ofover 10 percent.

The hummingbird of spray mixheads– MN6 CSM

The MN6 CSM was especially developedfor these applications. The mixhead forvery small outputs has an output rangefrom 40 grams per second at the upperend to below 10 grams a second at thelower end of the spectrum. Depending onthe PUR system, the spray output caneven be reduced to 6 grams per second –a novelty on the market. At the same time,the MN6 CSM is already fit for futureapplications, such as when it makessense to combine two PUR systems withthe same base components. With thisin mind, the MN6 CSM was designedas a multi-component mixhead for

PUR-CSM

Improvements in detail: the new MN8

Dashboard of the BMW 5 GT

acknowledging this, to Hennecke’s greatpleasure. In the manufacture of sandwichcomponents, the CSM plant technologyhas a market penetration of almost 90percent and practically sets the standard.At the same time, there is a growingnumber of classical production processesfor which PUR-CSM represents aconvincing alternative because Hennecke

spray technology adjusts to a particularapplication and not vice versa. Byconsistently expanding its CSM mixheadportfolio, Hennecke meets the concreterequirements of the market. Its “pureoutput” can be adapted to all thinkableand unthinkable application scenarios -maybe also to yours.

MN6 CSM with optional spray lance

*PUR mixture without chopped fibre glas

Mixhead Output* Numbers of Spray nozzle Maincomponents applications

Sprayed skinChopped fibre glas inopen mould technology

MN6 CSM 06 - 40 g/s 2 to 3 o

Chopped fibre glas in open mould technologyLong fibre technology (LFT)CSM-multi component technology

MN8 CSM 20 - 150 g/s 2 o

Paper honeycomp technologyLong fibre technology (LFT)Chopped fibre glas in open mould technologyCSM-multi component technology

MN10 CSM 30 - 350 g/s 2 to 4 o

Heavy layer partsSpray of filled materialMN10F CSM 30 - 350 g/s 2 to 4 —

Long fibre technology (LFT)Chopped fibre glas in open mould technologyMN14 CSM 150 - 800 g/s 2 —

— = not available o =optional equipment

Hennecke INNOVATIONS 109 18/19

Under the name 360° RETROFIT,Hennecke GmbH has set up anindividual sales area with its ownteam of designated experts. Theservice specialists want toconcentrate even more intensivelyon tailor-made retrofitting solutions.The MT, an efficient new mixheadseries that has an extremely widerange of applications and iswell-suited to the "Innovation forRetrofitting" slogan, has been in thespotlight right from the start.Customers are guaranteed excellentproduction results at a very attractiveprice/performance ratio.

focus is on securing Hennecke'shigh standards in the long term: "ForHennecke, Retrofit means optimizing ourproven machine and plant technologyeffectively in decisive areas and makingit appropriate for future applications.Customer benefit is always in theforefront." All the machinery and plantmanufacturer's Retrofit measures arebased on decades of experience,especially regarding the analysis ofconcrete customer demands. Carefully-constructed complete solutions ensuremaximum production results. In this way,Hennecke customers are offered far morethan simple replacement parts and in-stead presented with real innovations forretrofitting purposes.

The MT series is a particular highlight inthis regard. MT mixheads use state-of-the-art technology and improve it insignificant respects. The series isespecially suited to applications in theareas of refrigeration and moulded foam,and was developed for PU systems thatare more difficult and very difficult to mix.Thus, the MT is an optimal addition to theMX, which was designed for componentsthat are particularly difficult to mix. Theyoungest member of the Henneckemixhead family operates according tothe deviation principle, which fostersthe mixing process, calms the mixtureand ensures a laminar, non-splashingoutput. The development is basedon the state-of-the-art methods offlow simulation that have been createdin close cooperation with the renownedFraunhofer Institute. Decisiveimprovements have also been made withregard to the materials used and theoperation and maintenance of themixhead. The sum of the advantages forthe customer signifies a major increasein efficiency over similar competitivemodels in the market. Moreover, becausethe MT can also prove its superiority in

The term Retrofit generally describes themodernization or expansion of existingproduction systems. For the longstandingservice expert Peter Böhm, in charge ofHennecke's service sales department, the

Uncompromising where customer benefitis concerned - 360° RETROFIT

360˚ RETROFIT

Precision work:mixhead manufacture at Hennecke

"Optimizing plant technology effectively"Peter Böhm, Manager, Service-Sales

metering machines made by othermanufacturers, it is interesting for PUprocessors that have not used Henneckesystems technology before.

In the area of injector technology, theMT series is also very convincing.The injectors' so-called double-V-Adjustment guarantees maximum mixingquality and material utilization. Themodular injector design enables differentinjector sizes to be easily exchangedso that an optimum adjustment to therespective output is possible. Thus theuser can already achieve perfect resultswith the standard injector. However, theMT series also comes with the optionalinnovative constant pressure injector,which needs little maintenance thanksto flow-optimised geometry so thatproduction is considerably more efficient.Because of the lower overall operatingpressure, there is not only less wear and

useful spare parts packages. For the user,this means that orders are processedfast and simply and maintenance is easy.All MT-type mixheads are alreadyavailable. Further information aboutcurrent retrofitting measures can alsobe found on the back page of this issueof INNOVATIONS,by calling +49 (0)1805 339 200*or by visiting www.hennecke.com/360.

accumulation of noise in the meteringpumps, but the power consumption ofthe whole metering system is reduced aswell. On top of that, the constant pressureinjector offers the user more flexibility inthe production process because outputchanges are possible from one shot tothe next without the injector having tobe readjusted. Therefore, changes inproduction occur rapidly and at low cost.Moreover, the part is a winner when itcomes to reliability. Dirt particles in thecomponent are simply washed out by anautomatic readjustment of the throttlegap. In order to achieve a maximumdegree of automation, Hennecke's 360°RETROFIT also offers a pneumatically-assisted type of constant pressureinjector that allows the pressure to beremote-controlled from shot to shot oreven during shot operation. Of course, theexperts also provide further servicesregarding the new MT series as well as

MT 36-2

Well-equipped for each application: the line-up of the two-component MT series

MT 26-2 MT 18-2 MT 12-2 MT 8-2 MT 6-2

*(14Cent/M

in.fromaGerman

landline;different

prices

frommobile

networks.)

Minimum [cm³/s]

Maximum [cm³/s]

Max. (laminar) [cm³/s]

500

5000

2500

300

2600

1300

125

1200

600

50

600

300

25

300

150

8

50

50

MT 36-2Type MT 26-2 MT 18-2 MT 12-2 MT 8-2 MT 6-2

Special and multi-component mixheads are not illustrated; MT 12 and 18 are also available as multi-component mixheads

Output

The new Hennecke constant pressure injector offers you patented innovationfor fast and simple retrofitting. The low-maintenance injector optimizesmachine performance effectively and offers significant advantages to theproduction process at an extremely attractive price/performance ratio.

www.hennecke.com

• Maximum operating safety - because dirt particles are rinsed out thanksto the automatic readjustment of the throttle gap

• More flexibility - because changes of output are possible from shot to shotwithout any further adjustments having to be made to the injector

• Shorter cycle times - because the machine's lead time is reduced dueto a significantly faster pressure build-up

• Maximum efficiency - because there is less wear and tear and noisedevelopment in the metering pumps thanks to the flow-optimized injectorgeometry. A positive side-effect is a reduction in energy consumption

Innovationfor Retrofitting360˚ RETROFIT

* This is the price of oneinjector, ready to shipwithin 24 hours, excl. VAT.

Hennecke GmbH · Polyurethane Technology · Birlinghovener Str. 30 · D-53757 Sankt AugustinPhone: +49 2241/339-0 · Fax: +49 2241/339-204 · E-mail: info@hennecke.com

The constant pressure injector is 100 percentcompatible with Hennecke's standard injectors.They can be exchanged in little time without usingspecial tools.

>> For information about further attractive retrofit offers, please see www.hennecke.com/360