Innovation meets efficiency
The new generation of PANELMASTER STEEL plants sets new standards in steel sandwich panel
At a time when energy efficiency and sustainable construction are becoming increasingly important, high-performance insulation solutions are more in demand than ever. With the current generation of PANELMASTER STEEL systems, Hennecke-OMS presents a state-of-the-art production platform that redefines efficiency, scalability, and process reliability in steel sandwich panel production. The new generation of the system solution is the impressive result of the combined expertise within the global Hennecke GROUP competence centers and underlines Hennecke-OMS’s position as a turnkey specialist when it comes to the manufacture of sandwich elements.
Consistent plant concept – highly standardized and scalable
From the outset, the PANELMASTER STEEL was designed as a largely standardized and modularly scalable plant concept. The plant offers a fully integrated production solution from a single source and is aimed at users who are looking for an economical and flexible solution for large-scale continuous production. At its heart is a seamlessly integrated plant layout in which all production stations are integrated into a central control architecture. This ensures harmonized processes, maximum system availability, and increased operational reliability. With a typical annual production capacity of more than 2,000,000 square meters, a production speed of up to 15 m/min, and a variable panel thickness in the range of 20 to 300 mm, the new generation meets even the most demanding customer expectations.
FOAMATIC: Control intelligence on a new level
At the heart of the new control technology is FOAMATIC – an advanced operating and control platform with a modern Siemens HMI interface and the latest generation SCADA interface. “FOAMATIC is a key component for futureproofing our production systems. The latest Siemens technology, combined with an intuitive user interface and our early implementation, gives us a clear advantage,” emphasizes Daniele Balzi, Engineering Manager.
By deciding to use the powerful FOAMATIC control platform not only for metering machines but also for plant systems, Hennecke is taking a decisive step toward a uniform operating logic and menu structure throughout the entire production line. Based on powerful multi-touch HMIs, the FOAMATIC control platform offers maximum operational reliability, consistent standardization and automated product changeovers. Hennecke-OMS’ own Panel Management System controls the entire production flow efficiently and centrally: from order and recipe management to seamless tracking of individual panels.
“Our concept combines maximum production reliability with future-proof performance.”
Andreas Fischer,
Senior Director Sales Sandwich Panel Lines Hennecke GROUP
New standards in mineral wool processing
The growing demand for fire protection solutions is increasing the importance of sandwich panels with a mineral wool (MiWo) core structure. Hennecke-OMS is responding to this trend with a completely redesigned MiWo concept. “In dynamic markets in particular – especially in emerging countries – multifunctional systems that can process both PUR and mineral wool are becoming increasingly relevant,” explains Andreas Fischer, Senior Director Sales Sandwich Panel Lines. “Mineral wool also offers manufacturers higher margins and has become indispensable in this market segment.”
The new MiWo concept offers two key advantages: First, it delivers unprecedented process speed. “Our concept is designed for high production reliability and high speed across all product variants. For MiWo applications, this means an impressive range of 30 mm to 300 mm thickness at more than 10 m/min, which no one else on the market currently offers in this combination,” explains Fischer. On the other hand, the concept impresses with its consistent retrofit capability. Customers who wish to expand to MiWo production at a later date only need to take the installation area into account – the retrofit can be carried out without major intervention in production operations. “Our concept combines maximum production reliability with future-proof performance,” emphasizes Fischer.
PANELMASTER STEEL at a glance
- Standard production capacity: > 2,000,000 m² per year (based on individual production planning)
- Production speed: up to 15 m/min
- Panel thicknesses: 20-300 mm
- Panel length: 2,000-18,000 mm
- Panel width: 600-1,200 mm (standard: 1,000 mm)
- Facing thickness: 0.4-0.8 mm
- PUR/PIR foam density: 35-42 kg/m³
- System footprint (min.): 140 m × 35 m × 8 m (L × W × H)
- Control system: FOAMATIC, SCADA, Ethernet networking
- Mixing and metering technology: self-cleaning high-pressure mixhead, optional dual mixhead system
Technology with substance: efficiency in detail
The new generation of PANELMASTER STEEL features numerous technical innovations that underscore the focus on efficiency, precision, and sustainability:
- Profiling: Thanks to a high proportion of in-house production, precisely designed mechanics, and energy-efficient components, the profiling unit ensures consistently high product quality while reducing operating costs.
- Double belt technology: This technology is characterized by in-house slat production, which guarantees maximum accuracy and surface quality. Particularly maintenance-friendly: Individual slats are 100% replaceable – without having to completely grind the entire double belt surface.
- Mixhead: A patented, self-cleaning high-pressure mixhead significantly reduces material losses during changeovers, and also allows for very rapid changeovers. An optional double mixhead system allows continuous production without the need to stop the line to change the mixhead outlet device.
- Panel cooling and transfer: The system features a new panel transfer belt design. In addition, the cooling unit comes with an innovative design that does not require a pit to be added at the customer’s facility. This significantly reduces installation costs and maintenance requirements.
- Packaging: The newly developed modular packaging system uses vacuum suction cup technology for gentle panel handling. The wrapping unit was developed in-house by the Hennecke Business Unit China. In addition, a gluing machine, also developed in-house, is currently in the implementation phase.
Everything from a single source – from concept to retrofit
Hennecke-OMS offers seamlessly integrated production lines for the manufacture of steel sandwich panels as a one-stop solution – from plant planning and control technology to packaging. Users benefit not only from a uniform software architecture, but also from a central contact person for all project phases. “For many of our customers, the most important thing is that we deliver the entire plant as a turnkey solution from a single source. This simplifies the overall process considerably and ensures smooth operation – both during implementation and later operation,” explains Thomas Hachenburg, Vice President Project Excellence.
A central element of the Hennecke approach is the comprehensive 360° SERVICE concept, which supports customers throughout the entire life cycle. Starting with installation and commissioning, it also includes process planning, documentation, ongoing production monitoring, and qualified training programs. In addition, retrofit solutions play a central role in the system concept of the new PANELMASTER STEEL. Future expandability is already taken into account in the planning phase, e.g. for the subsequent installation of a MiWo unit. This allows systems to be flexibly adapted to new market requirements without significantly affecting ongoing operations. In this way, the PANELMASTER STEEL becomes an investment that offers not only flawless production results but also maximum long-term future security.
