Steadmans composite panel production is one step ahead with waterjet cutting solution

30th November 2011
Posted By : ES Admin
Steadmans has improved the quality of its range of insulated panels through investment in a waterjet cutting process with Wightman Stewart. An in-line waterjet cutting solution has given AS 35 insulated panels a superior finished product quality, offering major customer benefits.
An AS 35 panel consists of two coated steel profiles, including an external weather sheet 0.5mm thick and an internal liner 0.4 mm thick. Through a continuous process, a core of polyisocyanurate (PIR) insulation is introduced between the steel profiles and this system provides a high performance weatherproof envelope that can be rapidly installed.

For many years the company relied upon a “wet knife” system to cut the panels to size, but the finished quality was variable. Always looking to improve its processes, Steadmans made the decision to undertake a £¾ million upgrade of the composite panel production line, including the introduction of waterjet cutting through Wightman Stewart.
Waterjet is the ideal method for cutting the combination of the coated steel facings of the panels and their softer inner insulation core. A pure water in-line waterjet cutting system has been introduced whereby the waterjet cutting head follows a saw blade that rough cuts each panel as it is fed along the production line. Waterjet trims the insulating foam and provides a 90° smooth edge to the panel, removing any excess fill.

This means that on-site, contractors can achieve a much tighter fit when installing the panels, ensuring better and faster installation with no rework.

Wightman Stewart took into consideration the differing thickness of the AS composite panel range - from 40mm to 100mm - which had to be cut. The system also had to be in use to capacity five days a week, every week and therefore the ability to operate continuously and reliably under demanding conditions was also critical. The waterjet operates at 3000 bar pressure with the intensified water jet delivered through high-pressure flexible tubing and a cutting head with a 0.15mm orifice. To provide the necessary cutting pressure, Wightman Stewart recommended a 15hp intensifier, capable of delivering up to 3800 bar pressure.

To date, the installation has worked extremely well and the other major advantage for Steadmans is the improved cleanliness of the cutting process, with a substantial reduction in the amount of swarf generated within the cutting cabinet, whilst the water used simply evaporates.

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