LUBRICATION

SYSTEM
for
FPL HP

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 LUBRICATION SYSTEM for FPLHP

PREMISES
In the past three years Afros (and its
major competitors) have had to face a
growing problem with rigid low density
foam for refrigerators insulation:
The sticking of the film of foam

between the self cleaning rod and its

cavity

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LUBRICATION SYSTEM for FPLHP

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 LUBRICATION SYSTEM for FPLHP

Proper analysis shows that the the sticking of

the rod is closely related to the following
items
The increasing use of fast cycles and long

stroke for the mix heads

The use of long branched chains polyols

(necessary to maintain penthane in

solution)
The very fast reactivity obtained by special

catalysts
High functionality isocyanate
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LUBRICATION SYSTEM for FPLHP

Also our competitors (KM, Henneke)

faced the same problem but with even
more critical sticking

E.g. KM installs (only) lubricated mixing

heads for rigid foam and guarantees the
mixing head only 100.000 shots
The KM system (tested in Marystadt,
Sweden from 99) is still considered
critical by customers due to continued
maintenance requested

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 LUBRICATION SYSTEM for FPLHP

Afros, after a period of test and trials with

different systems, defined a specific mode of
use for the mixing heads and a lubrication
system to guarantee the mixing head for almost
300.000 cycles

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LUBRICATION SYSTEM for FPLHP

The specific mode of use is in reducing the

sticking of the film of foam
It consists of:
- standard stroke
- reduced speed of the self cleaning rod
(< 100 mm/sec)
- re-opening after pouring (within 8-12 sec
when the foam is still liquid)

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 LUBRICATION SYSTEM for FPLHP

FORCED LUBRICATION

The use of forced lubrication for

flushing the spacer applied together
with the others items is very effective

For our mixing heads it results in

being much less critical than for KM

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 LUBRICATION SYSTEM for FPLHP

We tested the system in our lab

First applied to our mixing head, then to the
KM style to understand the KM fault and we
found a real difference
Finally we transferred to the field to test
under real working conditions
The result is very satisfactory

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 LUBRICATION SYSTEM for FPLHP

Our mixing heads in general also perform well in

dry conditions
In dry conditions 88% reaches 250.000 cycles
(our warranty target)
The application of the lubrication gives a very
positive improvement (over 97% today reach the
300.000 shot target with the various lubrication
systems applied)
Compared with KM our mixing head transfers very
few P.U. chips in the oil; requests maintenance
five time less permits the use of vaseline,
mesamoll or DOP, raw polyol as lubricant

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FORCED LUBRICATION SYSTEM UNIT

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 LUBRICATION SYSTEM for FPLHP

The unit is composed by:

a case (capacity 12 litres) with the correct

chips separator
an inlet filter

a diaphragm pump controlled by a

pneumatic valve and a timer

flexible hoses

a return filter with by-pass

a frame to easy fix the unit overhead

electric low level

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LUBRICATION SYSTEM for FPLHP

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 LUBRICATION SYSTEM for FPLHP

TYPICAL APPLICATION
The forced lubrication unit is usually installed
on the rigid end of the piping and delivers the
flow through a flex hose up to the mixing
head

The spacer of the mixing head needs

modifications to hold the lubrication

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 LUBRICATION SYSTEM for FPLHP

TYPICAL APPLICATION

The suggested application is:

one system for two heads (one per side) on

a classical cabinet line
one for each drum

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 END

THANK YOU
FOR
YOUR
ATTENTION

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