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Cannon Viking Maximises Raw Material Efficiency

With the ever increasing costs of polyurethane foam raw materials Cannon Viking have been focusing in recent years in machinery efficiency to maximise foam yield and profitability for our clients Key areas of concentration with equipment design have been to

1) Further improve the foam block shape to enable the production of perfect rectangular shaped foam blocks.

2) Reduced bottom, side and top skins and therefore less raw material waste.

3) Reduce foam Pinholes and gas bubbles with Liquid Laydown technology available as an addition on all Cannon Viking Maxfoam continuous machinery

4) Create a Uniform and Regular Cell Structure available on both Low Pressure and High Pressure continuous foam production machinery with better mixing and pre mixing as well as custom made injectors on High Pressure continuous Cannon Viking foam plants

5) Further refine and develop Foam Plant Controls to ensure precision and yet simple foam plant operation

Foam block Shape: Cannon Viking offer various solutions to produce rectangular shaped foam blocks which can be part of a new continuous foam block production plant or added as a later addition to existing continuous machinery, the solutions are as follows:-

RS ( Rectangular Section) Side Film Equipment – this technology works on the basis of pulling the side shoulders of the forming foam block to improve the rectangular shape.

RS ( Rectangular Section) Side Film Equipment

Conveyorised Moving Sidewalls - High density flexible foams, Speciality foams such as Viscoelastic and HR foams as well as Semi Rigid and Rigid foams tend to be more difficult to process on a continuous foam block production plant. For this reason Cannon Viking provide the option of conveyorised moving sidewalls on all their continuous foam production plants. These conveyorised sidewalls are electronically synchronised with the bottom conveyor to ensure a smooth and uniform support to the foam. The Conveyorised Moving Sidewalls can also be varied in angle to counteract the trapezoidal block effect on heavy foams such as HR foams.

Improved Foam Cell Structure for High Pressure Continuous Machinery Cannon Viking have for many years been producing high pressure continuous foam production machinery with LLM liquid laydown technology know as our C-Max equipment range. From experience a key part of this technology to help ensure fine cell structure is the control of the high pressure injection where the material enters the mixing head, these units are critical to ensure good quality mixing but can be very difficult to set and maintain especially on key streams like TDI and Water. To overcome this very common problem Cannon Viking have developed their own solution with a range of custom made injectors. These injectors are very simple to use and maintain and can be manually controlled or motorised dependent upon the end client requirement. These injectors are manufactured in a range of sizes from very small chemical output for materials such as Stannous Octoate through to very high output materials like TDI and MDI with the added of benefit and simplicity of one injector unit being used for each metering line making set and operation much easier.

Foam Plant Control – OMEGA The Latest Generation

Conveyorised Moving Sidewalls

Reduced Pinholes and Fewer Gas Bubbles – Maxfoam Liquid Laydown Module Cannon Viking has undertaken extensive work to further improve the foam quality and therefore have less pinholes and gas bubbles in the foam. On our range of Maxfoam continuous machinery one major development has been the introduction of the addition of a Liquid Laydown Module known as LLM as a standard option which has proved very popular. Rather than just use the traditional Maxfoam Trough process with this LLM option the customer also has the capability to simply add an additional aluminium pour plate and attach the existing mixer unit to a liquid laydown unit for direct foam pour prior to the Maxfoam fallplate. This system gives the added benefit of allowing any gas bubbles to escape from the reacting foam prior to formation on the Maxfoam Fallplate

Cannon Viking continues to set the standard in Foam Slabstock technology with the latest version of the highly successful OMEGA computer control system which is now in operation with more than 170 clients worldwide. The OMEGA system has been developed in house by Cannon Viking with our own team of four specialist computer and software engineers and is fully supported from within the company

The latest enhancements to the OMEGA system include: • An easy to use industrial touch screen, designed for chemical environment from which full plant control and monitoring is undertaken

• A Modem to allow direct remote access via a phone line or via the internet – this allow our clients to observe and monitor production remotely - an invaluable tool in the modern factory where production is across different sites or even different countries. The Modem also enables direct support and assistance to be provided by Cannon Viking if necessary

• A UPS is provided as standard where power supply to the factory or foam plant may be an issue and problem

• Raw Material Tank Farm display can also be included to show tank levels and temperatures on the OMEGA control system

• Cannon Vikings VCO Block Cut Off Machine can also be integrated with the OMEGA control system which allows the Block Cut Off Machine to be configured and set up from the foam plant to cut the required number and lengths of foam block based upon the production and formulation database.

Planiblock Top Paper System – this technology works by applying a Top Paper or Top Film on to the top of the foam block during production with counter balanced ski's to flatten the top of the foam block. This technology also greatly reduces top skin waste and ensures that the block is totally rectangular in shape

Planiblock Top Paper System

• A completely modular and upgradeable Control System which can be easily expanded as further features such as additional metering units, square block equipment etc. are added to the existing foam plant

• All existing key features such as closed loop control, formulation management, full plant control and monitoring with data reporting remain

Maxfoam Liquid Laydown Module

Improved Foam Cell Structure for Low Pressure Continuous Machinery To further improve cell structure Cannon Viking introduced a special patented mixing unit back in 2008. The design of this patented unit is to give better mixing and control of nucleation air on Low Pressure continuous foam production machinery. This additional mixer unit is fitted prior to the main continuous machine mixing head and is used to create a homogeneous blend of air and activators which has proven to greatly improve the foam cell structure and quality. The equipment has been delivered as part of a large number of new Cannon Viking foaming plants as well as can be supplied as an addition to existing Cannon Viking Low Pressure foam machinery. This equipment is now in operation on Cannon Viking foam plants throughout Asia, Eastern Europe, Middle East and South America. Great improvements are seen in the overall cell structure which is much more regular as well as the added benefit of better control of nucleation air in low pressure machinery


OMEGA - Foam Plant Control

An OMEGA retrofit package is also available to enable the earliest versions of OMEGA control systems to be upgraded to the latest generation of controls, a specialist Cannon Viking controls engineer is provided with the retrofit package to install, commission and retrain the plant operators on site. With the increasing costs of raw materials set to continue for the long terms future Cannon Viking is hard at work trying to maximise efficiencies and developing cost saving initiatives which can be an integral part of a new foaming plant or can be added to existing machinery of Cannon Viking or non Cannon Viking supply. Please contact Cannon Viking or our local representative to discuss your requirements in more detail.

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