Polyurethane Processing

Systems for the highest demands

We encounter polyurethane plastics every day. Thanks to their almost unlimited applications, they have become an integral part of our lives. The production of high quality polyurethane foam products has been increasing in importance for years. The aim is to conserve raw material resources while producing foam products that meet industry requirements, for example with regard to weather resistance, temperature resistance, fire safety and minimal weight. Therefore, the manufacture of foam systems and complex product solutions makes high demands of developers, designers and technicians.

Optitek GmbH confronts these challenges. Over the years we have focused on the manufacture and processing of polyurethane, and have become mechanical engineering specialists in this area. Our products and systems enable the efficient production of rigid foam, flexible foam, integral foam, insulating foam and energy-absorbing foam. As manufacturers of polyurethane components, we also offer application-related additives, including catalysts, crosslinking agents and colourants as well as blowing agent combinations, foam stabilisers and flame retardants. Optitek also offers a tailor-made processing solution.    

 

   

In general we offer the following options:
  • Purchase of a new system
  • Purchase of a completely overhauled system
  • Rental of a new or completely overhauled system
  • General overhaul of your existing systems
We offer the following options for the systems we deliver:
  • On-site commissioning for the customer
  • A guide to production – for specialist system usage optimisation
  • On-site employee training for the customer
In this way, we support customers with our experience and technical expertise to ensure their complete satisfaction.
FOAM SYSTEMS

From effective entry-level models to fully controlled systems with process data acquisition

Optitek’s foam systems meet all the requirements for the production of polyurethane foam components, and are also unbelievably compact. All the necessary units are accommodated in a space of just 2.1 x 2.1 metres.
When developing our user-friendly, low-maintenance systems, we focus on the use of innovative, future-proof and high-quality technology.

A few highlights of our systems:

  • Assured performance and future-proof thanks to the use of state-of-the-art components and innovative technologies
  • Compact design: requires an area of just 2.1 x 2.1 m.
  • Machine frame easy to transport with forklift pockets
  • Accurate dosing thanks to state-of-the-art dosing pumps; option for frequency-controlled pumps with low-maintenance magnetic couplings
  • Double-shell day tank available on request for optimal temperature control of materials   
  • Interchangeable drip tray pursuant to German Water Resources Act (Wasserhaushaltsgesetz, WHG)
  • Smart internal pipe routing for flexible positioning 
  • Easy to use and maintain
  • Customised display in customer’s choice of language
  • Interface to downstream system peripherals
  • Wide range of optional extras
CONTAINER STATIONS

Optitek’s container stations for polyol and isocyanate are used to fill foam system day tanks. On the polyol side, a pneumatic lifting device with a collapsible stirrer ensures particularly short stirring times. On request, it can also be equipped with a beaker stirrer. After a stirring phase, the polyol is kept in suspension. The control system processes optical and acoustic messages and manages automated processes, such as container detection, reduction of the stirrer speed and level monitoring. The receptacle for the containers is inclined by approx. 2° and thus enables the efficient emptying of IBC containers.

Basic equipment of all Optitek container stations:

  • Pneumatic lifting device for the stirrer
  • Polyol stirrer with frequency inverter   
  • Distinctive CAMLOCK couplings
  • Powerful double-membrane pumps
  • Drip trays with grating pursuant to German Water Resources Act (Wasserhaushaltsgesetz, WHG)
  • Signal light showing operating status
  • State-of-the-art control system

Optional extras:

  • Gear pumps with low-maintenance magnetic coupling
  • Automated stirrer shutdown
  • Level monitoring of IBC containers
  • Dry-run protection to protect the pumps
  • Basket strainer on the suction side
  • Customised stirrer
  • Double-decker station design for shorter interval times
BARREL/RELEASE AGENT SYSTEMS

The "little brothers" to our container stations. Ideally suited for 200 litre polyol and isocyanate clamp ring barrels, but also as release agent stations, either individually or in a "double pack". Features include:

  • Precise double-membrane pumps
  • Pneumatic lifting device for the stirrer
  • Stirrer with gear motor
  • Silica gel filter on the isocyanate side
  • State-of-the-art control system

Naturally, we can also customise both the container stations and barrel/release agent systems according to your wishes. This includes not only a selection of different pumps but also, for example, customising the systems to your individual colour specifications.

PRE-MIXING STATIONS

Our pre-mixing stations are designed for processing/mixing polyurethane components with appropriate fillers or flame retardants. All commercially available systems suitable for polyurethane production can be considered as PU raw components.

Depending on the application, Optitek’s pre-mixing stations are available in various customised versions. 

A few highlights of our systems:

  • Transportable machine frame with interchangeable drip trays pursuant to German Water Resources Act (Wasserhaushaltsgesetz, WHG)
  • Low noise level thanks to closed system
  • Material input via state-of-the-art vacuum technology
  • Automated filter cleaning on request
  • Easy to use and maintain
  • Customised display in customer’s choice of language
  • Interface to downstream system peripherals
  • Wide range of optional extras

Optional expansion modules:

  • Bag emptying station or big bag station for storage of fillers
  • Screw conveyor for material conveyance
  • Containers with load cells for precise weighing of raw materials

 

BLOWING AGENT DOSAGE

In many cases, customers want to produce low-weight foams with very fine cell structures, which can be achieved by adding a so-called blowing agent to the polyol. The systems required for this are referred to as gas-loading or air-loading systems, since air or nitrogen is primarily used. The foam structure depends on how the blowing agent is added to the subsequent reaction mixture. In order to achieve optimal results, a gas loading unit is equipped with precisely adjustable air volume regulation device; digital flow regulators are usually used for the blowing agent. C-Pentane is another tried-and-tested blowing agent. It can generate an explosive atmosphere during processing due to the increased gas concentration, meaning that the system technology has to fulfil special safety requirements. In contrast, the Solstice®-LBA blowing agent, which is used to make e.g. insulating foam, is new on the market. Optitek GmbH offers the right system technology for each customer’s respective requirements. 

Furthermore, we have an expert team with many years of experience in the field of polyurethane processing, who will be happy to help you with any challenge that arises:  

  • PROCESS OPTIMIZATION
  • AUTOMATION
  • PROCESS ENGINEERING
  • MIXING HEAD AND PUMP TECHNOLOGY
  • E-PLANNING/CONTROL ENGINEERING
  • SYSTEM PROGRAMMING
  • GENERAL OVERHAUL AND/OR RECOMMISSIONING OF EXISTING SYSTEMS
  • SYSTEM PIPING
  • SYSTEM RELOCATION
In addition, we offer comprehensive assembly, repair and maintenance services.
© Copyright 2020
Optitek GmbH
Kiersperhagen 11 in D-58566 Kierspe
info@optitek.de

Management Building: +49 2359 2975903

Production Building: +49 2359 295361