Phenolic

Our background is that of being a world leader in the manufacture of Plywood to the highest quality standards. This resulted in the company having its own "Kite Mark" and full M.o.D. approval.

The technology used was based on Phonolic adhesive. Through the use of process control methods to monitor the resin to hardener mix and the press temperature, we achieved the high throughput and stringent quality standards required in the market place at that time.

The spread rate required for this product was 200 gsm @ £0.20 per m.sq.

The limitations of this process are;

1. Only flat panels available

2. Bonding limited to all wood composites

3. Unable to change to market requirements for multimaterial composites and forms.

PROGRESS

Films & Filled Epoxy

To overcome these limitations, we looked to the market place for standard "off the shelf" solutions.

To achieve formed panels; we invested in standard 2 Mtr long Bag Press technology.

To achieve the adhesive technology, we used the route of "Prepregs", Films and standard Filled Epoxy resins. We had to pre-mix the Filled Epoxy resin to use in our roller coaters.

The limitations of this approach are:

1. Poor bond strength.

2. Short shelf life.

3. High temperature to cure adhesive

4. Long cycle times

5. Loss of process control

6. High cost

TODAY

Wet Epoxy

Currently we have adopted the partnership approach with our adhesive supplier. This has resulted in the use of their Chemists, to tailor adhesives to our individual product requirements.

With this partnership we have gained the knowledge to specify a larger Bag Press, to meet market place requirements. Also new glue roller coaters that have temperature control and mix at the point of application.

This has given us back the process control that is required, to achieve the highest quality assurance, at the lowest cost, that is demanded in the market place today.

Through the Kaizan P.D.C.A. method, we can best use this control data to progress to further process and cost improvements.

Due to the demands of the market place, we have moved from one highly developed and controlled product field, into a New World of product flexibility. To achieve this, we have had to adopt new technology. This has required us to review our process methods and materials in line with today’s technology.

All change has to be controlled. To achieve this control we have adopted the “Kaizan” approach of Plan, Do, Check and Action (P.D.C.A.) to make these changes.

It will be seen from the information supplied that we have had to change our Glue system. The first approach was to follow the aerospace industry and use adhesive films. These proved to be expensive and required an increase in process time. The filled Epoxy’s offered some improvement, however it was not until we adopted the partnership approach, that we regained the full process control required to move forward in a controlled manner.

Whilst we have increased the glue cost by 29 pence per sq. metre, the reduction in process energy due to lower pressures and temperatures together with reduced volume of adhesive have off set this cost. This also helps to reduce emissions and help the environment. 

Process control data has shown that in winter the factory temperature is lower than in summer. We have also established that cycle time is increased at lower temperature and bond strength is reduced. By improving and controlling the temperature within our factory, we intend to improve cycle times and bond strength of the product by a further 5%.

Now that we have these improved products, we need to show the marketplace the advantages available. To achieve this, we have to compile a database, showing how these stronger and lighter panels can reduce lifetime costs. This is due to the fuel reduction achieved by the reduced vehicle weight, which can be quantified in operating cost reductions and environment improvements.

In partnership with the Process Technology Group, we need to design further process control methods and quality assurance procedures, to provide guidelines for achieving optimum product reliability.

Futher developments are required to achieve the full 3D forms that are required by our customers