CoreLess Technology
More Energy Efficiency with CoreLess Technology
If you want to gain a foothold in the established particle foam processing market and make your production efficient, you should use an economical system. With CoreLess technology from Kurtz, you get a system that is as powerful as it is sustainable for efficient processing!
When processing particle foams, everything revolves around the highest and most reproducible quality, the fastest possible cycle time, and maximum energy savings. This is precisely where CoreLess technology comes in, with consistent mass reduction, minimum possible steam chamber volume and thermal decoupling of the individual cavities. A decisive factor: The energy balance is determined 1:1 by the mass that has to follow the cycle-related temperature cycle from fusioning to demolding temperature of the particle foam material to be processed. An x-fold mass reduction in the system therefore also results in an x-fold energy saving. The thin-walled “coreless” mold design not only gives the technology its name, but also saves a considerable amount of mass.
Combined with the individual media connection from machine to individual cavities with optimized steam chamber volume, this ultimately leads to savings of up to 50% in the process media (saturated steam, compressed air and cooling water). As a logical consequence, this is directly and significantly reflected in the production plant layouts of companies that use CoreLess technology. On the one hand, significantly less powerful media generators are required and, on the other, valuable space is saved in the production hall.
Sustainably-optimized manufacturing process
Kurtz Shape Moulding Machines of the PRO FOAMER and POLY FOAMER types can sustainably ensure this optimized manufacturing process thanks to the direct media connection of the individual cavities, the reproducible, digital PID media control and the fast drive types (servo-hydraulic and electric drive). The tool technology was developed by our partner Doroteo Olmedo S.L. It has been successfully in series production exclusively on our systems since 2017 and has been continuously developed further. It is now in continuous use in numerous applications. Box and lid production, underfloor heating panels, facade and perimeter insulation panels, packaging parts and much more can be produced efficiently and flexibly.
Minimal use of media, shortest cycle time
In conjunction with the optional fully automatic tool adjustment, the order production of crates with different heights – or of panels with different thicknesses and with and without stepped rebate – can be fully automated without any set-up changes or operator intervention. And this saves material, without any cutting waste, as is the case with conventional EPS panel production from EPS blocks. Thanks to particularly short cycle times, the technology also makes it possible to react quickly to unscheduled requests and process orders. In the production of series packaging parts, including for white and brown goods, the technology impresses with its minimal use of media and short cycle times.
Sebastian Schreck, Area Sales Manager at Kurtz Protective Solutions, on CoreLess technology: “Our customers need and want sustainable process solutions, but also maximum flexibility. Machines with CoreLess technology can be converted to a system with a normal steam chamber if required, should the application or area of use of the machine change. Whatever the specific application, Kurtz is always close to the customer and the market requirements with its technologies.”