Kornylak Corporation  

Kornylak Corporation
400 Heaton St.
Hamilton, OH 45011

PH:  513.863.1277
TF: 800.837.5676
F:  513.863.7644

Process Tunnel®: Executive Product Summary

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Process Tunnel

Process Tunnel
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Executive Product Summary for Process Tunnel Insulation Equipment

Understanding Insulation Manufacturing Using the Process Tunnel Line
  • The Process Tunnel is a new generation production line for manufacturing urethane, isocyanurate, phenolic foam core panels
  • Process Tunnel uses an air film or air bearing to move the insulated panels through the pressure conveyor
  • The air film or bearing provides rapid heat transfer, faster line speeds and unmatched accuracy of 0.010 of an inch
  • In addition, the air bearing does not leave belt marks of a standard pressure conveyor
  • The air film design allows for production of much thinner foam core panels than a standard pressure conveyor
  • Smooth, flat and flexible substrate materials work best in the Process Tunnel
  • The Process Tunnel line consists of multiple pieces of equipment working together for the manufacture of insulated foam core panels
  • Polyurethane, isocyanurate, phenolic, or similar foam materials may be used in the production of foam core panels
  • Chemicals are pumped from day tanks through a dispensing unit and into the mixing head mounted on a traverse
  • The traverse moves rapidly across a laydown table to distribute the foaming chemical mixture
  • The laydown table brings the top and bottom panel skins together with the expanding foam
  • The foam insulation is spread across the bottom skin before it enters the process tunnel
  • Inside the pressure conveyor the foam mixture expands filling the area between the two skins
  • The length of the Process Tunnel depends on the chemical mixture used and the production speed needed
  • Upon exiting the Process Tunnel, the foam panels are allowed to cool and stabilize on a roller conveyor
  • If needed, the sides of the foam panels are trimmed with edge saws
  • Then the insulated panels are cut to length
  • At this point the individual foam core panels continue down a run out conveyor where they can be stacked manually or mechanically
  • High production speed, better heat transfer, higher accuracy, and thinner panels
  • On the fly, variable length production
  • You can use a wide selection of smooth, flat, flexible panel skins
  • Assured accuracy during production
  • Flexibility of chemical formulations and production speeds
Product Applications
  • Some examples of how foam core panels are used: exterior or interior walls, ceilings, floors, HVAC ducts, and backing for vinyl siding

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