Reactor E-30 makes polyurethane foam insulation affordable and easy to apply

A solution for a low cost, operator-friendly method to inject polyurethane foam into aluminium building panels helped an Egyptian manufacturer improve its processes.

An Egyptian aluminium building panels manufacturer's method was not only labour intensive but required that the manufacturer would outsource large quantities of pre-moulded PU foam panels. These panels were supplied in one shape only, then had to be cut to size to fit into the various panels manufactured. 

Challenge: reducing high costs

Due to the challenges and obstacles faced with previous PU foam application equipment, the manufacturer preferred to continue purchasing pre-moulded PU foam panels from abroad at great expense. This was until the local Graco distributor proposed the Graco Reactor™ E-30. The Egyptian manufacturer had nothing to lose in agreeing to a demonstration with the Reactor E-30, as his imported 40-foot container of PU foam panels was delayed at customs, and production deadlines were nearing a close. 

Gaining time and efficiency

A Reactor E-30 with a Fusion Mechanical Purge Gun and a pouring kit was used for the application. By drilling blowholes in the aluminium frame, a modified pour nozzle kit (248682), fitted with a disposable synflex tube, was inserted. The top of the frame was then covered with a greased barrier plate. This was to ensure that the foam caked evenly to the top.

The foam was then injected into the various compartment frames. The process took 10 seconds per compartment; the previous method took the operator on average 30 minutes per compartment, as it entailed manual cutting and fitting of the PU foam panels. 

An enormous gain of time thanks to the mechanical purge gun, which ensured continual production from start to finish.

User-friendly controls

The operators found the Reactor E-30 controls and overall system user-friendly and after six continual production days, the decision by this manufacturer’s management – after consulting with their operators – to purchase the Reactor E-30 was unquestioned.

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