Specifically, the transition has created a simplified application process, improved environmental conditions and eliminated solvent cleaners.
For two decades, Chemique has supplied adhesives to Mannok for its thermal laminate plasterboard manufacturing facility in Ireland. Since the beginning, Chemique has been involved in the bonding process of its thermal laminate composite board, which has evolved over the years into an automated bonding line.
In 2012, Chemique collaborated with both Mannok and Finishing Design Services (FDS), a specialist machinery manufacturer, to develop an automated process for bonding plasterboard to PIR insulation.
This two-component polyurethane adhesive system proved successful for many years, however, advancements in adhesive and machinery technologies led to the creation of a new, production line.
Considering future requirements for output and environmental impact, Mannok, FDS, and Chemique Adhesives determined that adopting a PU bead system would be the optimal choice for the new process.
James Thorpe, sales manager at Chemique, said: “During the initial testing stages, we were pleased with the performance of the single-part polyurethane adhesive and its excellent bond to the laminated panel. Tailoring the open time and cure time to meet the specific requirements of the application proved successful, and we were delighted with the final outcome.”
The adhesive used is from the Solfre range of polyurethane adhesives and its formulation is said to provide superior resistance to chemicals, heat, humidity and thermal shock.
FDS designed a new laminating production line incorporating the latest technology, and providing an efficient system for Mannok to meet the growing demand for bonded PIR insulation for their clients. This new machine integrates the latest adhesive technology from Chemique, ensuring the production of panels.
According to Chemique, the new manufacturing system boasts numerous improvements over its predecessor, providing reduced adhesive coat weights with higher bond strengths, lower heating costs, increased production capacity, and an improved working environment for employees.
The system is also claimed to ensure a more even distribution of adhesive onto each board and the improved manufacturing control capability allows for less employee intervention and reduces downtime.
Gordon Wiggins, production manager at Mannok, PIR Insulation facility, said: “The implementation of the new line aligns closely with the Mannok 2030 Sustainability Vision and our commitment to the three pillars of our people, the planet, and our partners. It has greatly enhanced our overall manufacturing efficiency, allowing us to produce a resilient PIR laminate plasterboard using 50% less adhesive per unit and requiring 60% less electrical energy compared to the previous system.
“It also facilitates an improved working environment during manufacture for employees as well as reduced long-term environmental impact and zero chemical emissions from the production process.
“Furthermore, it has also increased our laminate plasterboard production capacity meaning we can manufacture higher quality laminate composite products which are more readily available for our customers and to meet market demand.”
