 the adhesive system that makes the difference Producing very high quality sandwich panels depends upon bringing together a multitude of different functions, processes and materials. These include production line design; CAD software and skilled production staff along with the materials used such as galvanised steel; aluminium; extruded polystyrene and EPS. All this counts for nothing, however, if they are not correctly bonded.
By working closely together, EDM Spanwall and Chemique Adhesives have developed an adhesive and application system that makes a significant contribution to the production of superior sandwich panels.
EDM Spanwall
EDM Spanwall Limited, part of the EDM-CECO Group, are market leaders in the design and manufacture of a wide a range of architectural wall cladding systems. These are produced at their 7500m2 purpose-built  manufacturing facility in Northern Ireland. Panel systems have been supplied to projects undertaken by world-class companies for the past 30 years, including British Airways, Tesco, GSK and most recently the Manchester City Football Ground, which was previously used for the Commonwealth Games.
The company’s commitment to achieving product excellence through continual product and process improvement, along with an innovative approach, led, eighteen months ago, to the start of an investment programme that is revolutionising production and customer service. The programme involved the installation of a completely new Spanwall composite panel production line that produces not only an extremely high quality product, but the technical and logistical capability to provide customers with a complete panel package.
Chemique’s Total Package of Adhesive and Equipment.
‘We realised that although adhesive is probably less than 3% of finished product costs, it plays a key role in achieving panel excellence. Therefore, to improve product quality, speed up production and increase capacity, we put considerable effort into discovering the best adhesive to use and developing the optimum bonding line for its application’ states Lisa Rafferty, Spanwall’s Production Manager. ‘After approaching several other adhesive producers, we started working with Chemique Adhesives & Sealants. They were the only company that provided the whole bonding process, including adhesive,  application equipment and the necessary technical and engineering back-up and training’, she adds.
Spanwall have now switched to using Chemique’s own solvent free two-part polyurethane adhesive, Solfre2. This is applied by a Jet Applicator, the ‘intelligent’ application system developed by Chemique’s engineers. Previously, Spanwall were using a standard automated system to spray one component, moisture cure adhesive, to bond polyester coated metal to CFC and HCFC- free insulating cores. The bonded materials were then put into a cold press for two hours, giving average production of 800-900 m2 /week
With the combination of Solfre2 and the Jet Applicator, Spanwall achieves a 30% quicker cure and a 50% reduction in coating weight, for the same area of application. This saving is mainly due to the way the glue is sprayed. The Jet Applicator applies adhesive evenly across the panel, with no overspraying, to produce a stronger and more uniform bond.
The Results
‘Switching to the Solfre2 system has made a major impact on our production levels and costs. We are now able to produce 2000m2 week, while reducing adhesive usage by 60%, if you take into account the 25%  overspraying we used to have with the old line. Additionally, press time has been reduced to 12min/stack, resulting in fewer operatives being tied up on the line, thereby giving them the opportunity to concentrate upon other parts of the production process” stated Lisa.
As a result of this investment and the work carried out with Chemique, EDM Spanwall’s management have far exceeded their initial expectations, not only have panel quality improved and production rates doubled, significant savings on adhesive usage have been achieved while eliminating emissions of volatile organic compounds. They are now confident that their customers can be supplied with the most advanced, custom made, cladding systems in the UK and Ireland. This will help to ensure that the Company retains its position of market leadership in the Home market, while helping towards achieving the same position in the rest of Europe.
Chemique continues working to provide customers with all their adhesive needs - from tailored adhesive formulations to the development and installation of specific application equipment, along with comprehensive service support and training.
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