Innovative solutions for polyurethane processing.
Together with leading global manufacturers and partners, Fill develops concepts and solutions for current and future requirements for highly efficient systems.
We have been building special machines and complete systems for polyurethane processing for more than four decades. Our focus is on thermoplastic particle foams, utilizing our experience in foam part production. Fill's pioneering technologies promote the sustainable use of recyclable materials.
PARTICLE FOAM MANUFACTURING SYSTEMS
Fill provides tailor-made system concepts for producing components from particle foam, including surface layers and functionalization. From vaporless pre-foaming by means of IR radiation through to the fully tested final component, the entire process chain can be represented here. From the material producer through to toolmaking, we ensure correct selection of the supply chain in our role as general contractor.
In this process, Fill works with all the renowned companies and institutes in the industry. Issues such as sustainability, resource conservation, and energy efficiency are just as important in system planning as the possibility of complete digitalization. This means that you always have your production under control, while also protecting the environment.
PREFOAMING
The infrared pre-foaming process patented by Fill offers the advantage that the foam beads can be processed immediately without any drying time. The IR-EXPANDER does not require any complex infrastructure for steam generation.
Due to the high penetration depth of the IR radiation into the granulate, the thermoplastic matrix softens evenly, which leads to improved mechanical properties depending on the material. All thermoplastic particle foams with blowing agent can thus be foamed.
The IR-EXPANDER is available in two sizes - 340 and 1,400 mm application width. The system can be equipped with further options, such as automatic density control, an extraction system for materials with flammable blowing agents, and individual conveyor systems.
AUTOMATIC DENSITY CHECK
Fluctuations in the raw materials manifest themselves in the form of different particle sizes and blowing agent loads. To compensate for these deviations, it is necessary to permanently monitor the density foamed with the IR-EXPANDER and feed the measurement results back into the control loop.
We use the load cell principle as standard for this process. A microwave-based system can also be used as an option. This has the advantage that it can compensate for environmental influences such as temperature fluctuations or vibrations in the production area.
TOOL FILLING SYSTEMS
The filling system is a key issue when processing particle foam. We offer customized solutions for a wide range of materials and volumes.
Tool filling systems from Fill are characterized by numerous advantages:
- Good accessibility for cleaning and maintenance
- Quick and easy material or color change
- Pulse disk driven by an adjustable electric motor and easy to replace
- Each pressure vessel can supply up to 20 fillers.
If required, each filler can be controlled separately. Four pneumatic functions are available for each filler. Thanks to the integrated fill level measurement in the pressure container, it is possible to choose whether the container should be refilled after each filling cycle or only after a certain number of filling cycles.
The tool filling systems can be integrated into existing machines or designed as a stand-alone system. In Fill's molding machines, the control of the filling system is integrated into the machine control system.
MOLDING MACHINE
The horizontal mold carrier is designed precisely for the production of large-area particle foam components with one or two cover layers with variothermal mold temperature control. Particular attention was paid to fast mold changes and ergonomics.
The system consists of a base frame with linear guide for a movable mold fixing platen 1 and a fixed mold fixing platen 2. The mold fixing platen 1 contains the hydraulic control axes for the compaction stroke. The tempering units can be mounted on an attached platform. The mold mounting platen 2 is permanently mounted on the base frame. The dosing technology is guided laterally into the molds.
The tools are centered by means of hooks and bolts and fixed using rotary lifting clamps. The tools are changed using a crane.
The size of the clamping surface can be freely specified by the customer. Fill also offers the appropriate filling system as an option.
MOLDED PART PRODUCTION SYSTEM - ROUND
The rotary cycle concept offers a proven solution for the production of particle foam components in large quantities because it makes the best use of the peripheral equipment.
The system can either be supplied with steam or equipped with variothermal temperature control units. Only one filling system supplies the molds, even if six molds are in use, for example. Only one robot is required to insert the inserts and remove the finished components.
Precise positioning of the rotary table is achieved via incremental position measuring systems and servomotors. The molds or mold carriers are either permanently mounted on the rotary table or are changed fully automatically via a manipulation system.
A quality inspection system can be integrated into the system as an option.
MOLDED PART PRODUCTION SYSTEM - LINEAR
The steam-free molded part production system is specially designed for the production of small components made of particle foam, which are to be produced in large quantities.
In this system example, two vertical mold carriers are used. A high degree of parallelism of the mold mounting platens and their rigidity enables to produce high-precision components.
The variothermal molds are heated and cooled with powerful temperature control units. The tools are filled volumetrically or gravimetrically via articulated robots into the open tool using a high-precision dosing system, as is the removal of the components.
A vibration unit can be integrated as an option for even distribution of the material in the mold.
For dosing into the closed mold, the system can be equipped with a standard filling system from Fill if required.
IR-WELDING SYSTEMS
Years of experience in the use of infrared radiation make Fill a competent partner when it comes to welding particle foam components.
We rely on medium-wave infrared rays that are aligned horizontally. Thanks to the fast response of the emitters and digitized control, the process is extremely energy-efficient.
Depending on the application, area-following or contour - following emitters are used.
Each infrared welding system is designed exactly according to the customer's requirements.
DIGITIZATION AND QUALITY INSPECTION
Systems for automated quality inspection of particle foam components are individually designed according to our customers' requirements.
A wide variety of measurement methods, such as ductile systems, image processing, various temperature measurement methods and scanner technology, are used. A rotation function can be integrated to carry out a 360° analysis.
The measuring systems can also be integrated into tempering and drying ovens to evaluate the geometric behavior of the component during the tempering or drying process or to check the quality of the components.
Depending on customer requirements, the components can be inserted into or removed from the system either manually or fully automatically.
The CYBERNETICS software solution developed by Fill offers the user a wide range of evaluation methods and analysis functions.
POLYURETHANE MANUFACTURING SYSTEMS
Fill's product portfolio includes a wide range of stationary and mobile mold carrier systems - the right solution for every product.
Automation is essential in the production of components. We offer numerous options for the corresponding production environment, such as release agent application, painting, foam application, mold cleaning, quality control or component manipulation.
PUR ROTARY TABLE SYSTEMS
Fully automated PUR rotary table systems for the production of large and small parts are characterized by maximum availability and a wide range of technical options.
The focus of the design is on flexibility with maximum system utilization. The change of molds and mold carriers is cycle time-neutral.
The exact positioning of the rotary table is carried out via incremental position measuring systems and servo motors.
The molds or mold carriers are either permanently mounted on the rotary table or are changed fully automatically via a manipulation system.
Customer-specific mixing and dosing systems, extraction systems, other process modules, and a quality inspection can optionally be integrated into the rotary table systems.
PUR OVAL TRANSPORT SYSTEMS
Oval conveyor systems from Fill are developed and built according to individual customer requirements. The number of mold carriers and the degree of automation is adapted accordingly.
Oval conveyor systems can be equipped with a fully automatic mold carrier changer. This unique system enables the change of mold carriers including molds during the production process, without stopping the system.
A linear change manipulator docks onto the oval conveyor.
The mold carrier trolleys are transported out of the system guided by rollers and the new mold carrier is inserted.
FLEXIBLE MOLD MANIPULATION SYSTEM
Variable process times require flexible solutions. Fill production systems are adapted to specific customer requirements and take different reaction times into account.
The molds are manipulated between the mold closing station, the reaction bearings, and the service stations using robots located on a 7th axis.
The system is operated intuitively and is extremely flexible.
Components with a longer process time are left in the reaction store for longer. Due to external connection of media, heating and electronics, any tool can be processed at any position.
Fully automatic cleaning, applying release agent, IMC coating and component removal can also be integrated into the system as an option.
The modular design of the flexible mold manipulation system allows a quick product change.
FILL CYBERNETICS
FILL CYBERNETICS products are an essential feature of Fill’s machines and systems. They cover the entire bandwidth of required solutions – from the monitoring of complex individual operations and seamless component traceability, through to automated system optimization by means of artificial intelligence (AI). Not only standard solutions, but also customer-specific and platform-independent dashboards, provide an optimum overview and enable detailed analyses of production and machines. This guarantees high availability and increases your productivity. In the FILL FUTURE ZONE – a center for digitalization, research and development – experts and data scientists are busy creating and improving our digital products.
The use of innovative technologies and many years of experience in special machine construction and the handling of complex projects make Fill a competent and reliable partner. Our strength lies in recognizing synergies from the various branches of production and putting them to good use.
If you are seeking the best solution, shape your future with Fill.
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