BBG GROUP
THERMAL INSULATION
Universal tool for thermal insulation of water storage tanks
For manufacturers and suppliers of solar systems, heat pumps, oil and gas heating systems, solid fuel boilers, and components for hot water supply in low-energy houses, we have developed a new product: our toolmaking division designs and manufactures versatile foaming tools for insulating water storage tanks of different sizes with rigid polyurethane foam (PUR).
Universal tools can be adapted with just a few simple steps
We design our universal tools so that they can be adapted with just a few simple steps to different tank sizes, model variants, and connection types. They can be operated manually or – with the support of a PLC control system – semi-automatically, and optionally hydraulic or pneumatic.
Polyurethane provides excellent insulation
The layer of fine-celled rigid polyurethane foam with a closed-cell structure that forms when the tanks are overmolded slows down gas transport. This results in excellent insulating properties, ensuring that the stored hot water retains its temperature for a long time.
PUR universal tools increase cost efficiency
Foaming with just a few universal tools increases the cost efficiency of water tank production. Especially when manufacturing small batch sizes with a wide variety of types, tooling costs can be significantly reduced. In addition, the easy handling of the tool and integrated sensors for process monitoring and control ensure short setup times.
Proven experience with universal tools
BBG’s universal tools for foaming potable and process water tanks have proven highly effective. They are already in use with a number of satisfied customers.
Insulation for tanks ranging from 100 to 1,000 liters
The highly versatile molds can foam up to 15 different tank models with capacities ranging from 100 to 1,000 liters. The tanks are used in combination with solar systems, heat pumps, oil or gas heating systems, and solid fuel boilers, as well as for hot water supply in low-energy houses.
Producers can significantly reduce tooling costs
Most manufacturers of hot water storage tanks offer their customers a wide range of different model variants. These differ in terms of size, equipment, and the positioning of connections for inlet and outlet pipes, threaded sleeves, temperature sensors, and other components. "Many manufacturers have more than a hundred tools for insulating their tanks. This means an enormous amount of capital is tied up in molds that are often only suitable for a single tank model", explains Gerhard Hörtrich, Sales and Project Manager at BBG, describing the situation in the industry.
We work closely with our customers
We develop the universal tools in close cooperation with our customers. This includes clarifying which sizes and insulation thicknesses are required, how many tank variants are needed, and which equipment options are desired.
Exact specifications and high precision
Based on the specifications, our experts design exactly the tool required. To ensure it can be used universally for all variants, the foam top edge can be adjusted to the tank height with a movable cover. In addition, type-specific components are accommodated with exchangeable inserts that can be placed into the tool for each model. To prevent polyurethane from leaking out despite the high internal pressure during foaming, we place great emphasis on the high precision of all parts.
Semi-automated production
For foaming, the water tank is placed on the extendable base plate of the tool and rolled into the open, upright mold halves. For model-specific features, type-coded inserts are mounted into the mold as required.
In semi-automated production, the PLC control system checks whether the tool has been correctly prepared. Sensors automatically detect the tank model and the position of internal components. A status query with position control verifies that the clamping device has properly closed the mold. Only when the control system gives clearance can foaming begin. While the PUR is injected into the tool and cures, heating mats on the outside ensure a consistent temperature and an optimal foaming process.