An innovative process for the automatic loading and unloading of multi-daylight presses optimises the production of transformer boards, an important cellulose-based insulating material. The technology developed by SYSTRPLAN decouples the wet area from the press, enables gentle transport of the sensitive material and maximises production efficiency through simultaneous loading and unloading.
Transformerboard is made from high-quality cellulose, which is first processed into wet layers (wet fleece). These wet fleeces are pressed into dense, robust boards under pressure and heat in a multi-daylight hot pressing process.
The challenge here is that the multi-daylight press only works optimally if the wet fleece is fed in at precisely timed intervals and the finished boards are removed quickly. Conventional processes, in which the press is first completely emptied and then refilled, lead to unnecessary downtime..
Synchronised processes for maximum efficiency
The SYSTRAPLAN system solves this problem by intelligently decoupling wet nonwoven production from the hot press. While the press is operating, the wet nonwovens are continuously prepared in the wet area. At the heart of the system is a loading basket that can carefully hold the damp, sensitive sheets. The wet layers are collected in this basket while the press is closed. Once the pressing time has elapsed, the decks open and the loading and unloading processes take place synchronously..
Unloading: The finished transformer boards are pulled out of the press stages using vacuum suction cups and transferred to a removal basket.
Loading: At the same time, the belttrays with the new, unpressed layers move from the opposite side into the empty floors of the press..
This parallel approach significantly minimises press downtime. Once the old sheets have been removed and the new layers positioned, the pressing process can resume immediately. This optimises cycle times and increases production capacity.
Gentle transport of wet fleece
Special attention is paid to the careful transport of the sensitive wet fleece. Wide conveyor belts support the entire surface of the panels, and precise transitions between the belts ensure safe transport without damage. Before the pressing process, the panels, which are up to 6.5 metres long and 3.4 metres wide, are cut to their final size using special cutting units. The resulting material is collected and sent for recycling.
Low maintenance and long-lasting
The entire system is characterised by its robust, low-maintenance and durable design. As the plates are used as insulation material for electrical components, care was taken during construction to avoid metallic abrasion on all moving parts.
Flexibility of system configuration
Another advantage is the high flexibility of the system configuration. SYSTRAPLAN systems can be individually adapted to customer-specific requirements, whether in terms of panel sizes, weights or the number of press stages – up to 20 stages are possible. This tailor-made solution ensures that transformer boards are produced efficiently, to a high standard of quality and in line with the specific needs of the customer.
Transformerboard is made from high-quality cellulose, which is first processed into wet layers (wet fleece). These wet fleeces are pressed into dense, robust boards under pressure and heat in a multi-daylight hot pressing process.
The challenge here is that the multi-daylight press only works optimally if the wet fleece is fed in at precisely timed intervals and the finished boards are removed quickly. Conventional processes, in which the press is first completely emptied and then refilled, lead to unnecessary downtime..
Synchronised processes for maximum efficiency
The SYSTRAPLAN system solves this problem by intelligently decoupling wet nonwoven production from the hot press. While the press is operating, the wet nonwovens are continuously prepared in the wet area. At the heart of the system is a loading basket that can carefully hold the damp, sensitive sheets. The wet layers are collected in this basket while the press is closed. Once the pressing time has elapsed, the decks open and the loading and unloading processes take place synchronously..
Unloading: The finished transformer boards are pulled out of the press stages using vacuum suction cups and transferred to a removal basket.
Loading: At the same time, the belttrays with the new, unpressed layers move from the opposite side into the empty floors of the press..
This parallel approach significantly minimises press downtime. Once the old sheets have been removed and the new layers positioned, the pressing process can resume immediately. This optimises cycle times and increases production capacity.
Gentle transport of wet fleece
Special attention is paid to the careful transport of the sensitive wet fleece. Wide conveyor belts support the entire surface of the panels, and precise transitions between the belts ensure safe transport without damage. Before the pressing process, the panels, which are up to 6.5 metres long and 3.4 metres wide, are cut to their final size using special cutting units. The resulting material is collected and sent for recycling.
Low maintenance and long-lasting
The entire system is characterised by its robust, low-maintenance and durable design. As the plates are used as insulation material for electrical components, care was taken during construction to avoid metallic abrasion on all moving parts.
Flexibility of system configuration
Another advantage is the high flexibility of the system configuration. SYSTRAPLAN systems can be individually adapted to customer-specific requirements, whether in terms of panel sizes, weights or the number of press stages – up to 20 stages are possible. This tailor-made solution ensures that transformer boards are produced efficiently, to a high standard of quality and in line with the specific needs of the customer.
