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However, before the 75-metre-long line could be installed, the hall intended for it had to be completely renovated. The lamination area is now separated from the outside and from the raw material warehouse by airlocks. Five pits of different sizes and depths had to be integrated so that the entire process can be operated at ground level. These pits are used for feeding and stacking, for example. The heart of the system, the BÜRKLE laminating station, measures an impressive 15 meters. It took around 12 months from planning and commissioning to delivery. The installation of the line alone took five months.
And this time was well invested, reports Richard Eckertz from Business Workhouse, temporarily responsible for part of the growth investments made in Weinsheim. Today, the laminating line can produce up to 10,000 panels per day using the current working time model. The panels have a maximum size of 3,300 x 1,300 millimeters. The cycle rate for feeding and stacking is adapted to the laminating speed and is a maximum of 15 cycles per minute. Depending on demand, the system is currently operated in three shifts on five working days. If the order situation makes it necessary, special shifts are also possible.
Different core boards
The actual lining and cladding panels are made of chipboard, MDF or HDF, depending on the door model. All panels are laminated on both sides in the machine. The top side is given either various decors or surfaces made of CPL laminate or lacquered film. A backing paper is applied to the underside to prevent warping. In addition, the BÜRKLE line also produces door top layers with a base made of HDF or MDF boards with a thickness of 3 to 4.5 millimeters. However, only one side of the door top layers is laminated with the corresponding surfaces. These are then joined to the middle layer of the door leaf in the door leaf production process and further processed. The actual door panels of different sizes and thicknesses are then also cut into corresponding lining and cladding parts and finished in the frame plant.
After preheating in the plant, the panels are glued. Around 50 grams of PVAc adhesive are applied to both sides of each square meter of panel, followed immediately by drying in the infrared zone. Depending on the surface, lamination can now take place at a temperature of 50 to 150 degrees. The panels then enter the fully automatic edging system. Here, the excess film is removed from all four sides of the panel. At the same time, the length, width and angularity are trimmed to their final dimensions. The boards are then ready and are transported via the destacking area to the so-called frame end department for further processing.
As a rule, the gluing unit has to be cleaned once a day.
Best experience
The FFA 1300 thermal laminating system has been running smoothly for around a year. Twelve employees operate the system on a rotating basis. It took about four weeks to train the permanent staff in the technology. For the most part, PRÜM was able to draw on experience from existing processes for the specific product. "In combination with the specialists from BÜRKLE, the training was very efficient," says Richard Eckertz. The plant then carried out further training for the three-shift operation on its own.
A multi-level press from BÜRKLE was already installed at PRÜM Türenwerke in 2013. "We really had the best experience with this line, so it was clear to us that we would also rely on the robust and reliable machines from BÜRKLE again for the required laminating line," summarizes Richard Eckertz. Further requirements for the manufacturer from Freudenstadt in the Black Forest were a product-specific design and high output combined with corresponding process reliability. A durable design in combination with solid and uncomplicated technology, short delivery times and fast installation including commissioning by the fixed date were further aspects that were met to the client's complete satisfaction. The focus on the essentials and the associated good price/performance ratio were further arguments in favor of the technology from Freudenstadt. Of course, those responsible at PRÜM Türenwerke also looked at reference systems at customers' premises. "The reliability and speed of the laminating lines in operation really impressed us, so that we ultimately placed the order with a high degree of conviction," continues Richard Eckertz.
Perfect service
The laminating line is equipped with the BÜRKLE remote service system in case any problems should occur. This system provides access to all relevant line elements for fault diagnosis and troubleshooting. For this purpose, the BÜRKLE technicians in Freudenstadt have direct access to the line control and the operating terminals via a remote desktop. "This remote access option gives us as a door manufacturer the security of knowing that we can keep any downtimes to a minimum and that our ambitious targets in terms of delivery capability are not jeopardized," concludes Richard Eckertz.
PRÜM Türenwerke's product range is rounded off by an extensive range of glass and fittings. In addition, innovations such as a digital portal enjoy high strategic priority. In addition to the continuous digitalization of its own company, the company's goal is also to support its partners in the specialist trade with innovative consulting and sales aids. The manufacturer has been part of the Swiss company Arbonia AG since December 2016.
