Sustainability Dieter Siegmund 24.10.2023

Produce more resource-efficiently and more environmentally friendly

Plant and automation solutions in harmony with the environment

Increasing resource efficiency and reducing environmental impacts are two of the key starting points for sustainable automotive production. Innovative technologies and processes make it possible to design production processes in the automotive industry in such a way that these goals can be achieved efficiently and vehicles can be manufactured in an environmentally friendly manner.

As a leading manufacturer of acoustic foaming systems, Polyplan supports renowned automotive manufacturers in their sustainability-oriented endeavours. After all, the improvement in the comfort and safety of vehicles, to which these systems contribute by introducing acoustic foam into vehicle cavities, must not be at the expense of the environment and resources. The sustainability of acoustic foam systems in the automotive industry

Polyplan acoustic foaming lines

support the sustainability efforts of car manufacturers in vehicle production in many ways. Ongoing research and development will help to further improve the performance of the equipment and minimise resource consumption and environmental impact.

  • Polyplan acoustic foaming systems can be operated with recycled materials such as polyol and isocyanate recyclates. The unrestricted use of regenerative materials saves up to 20 %
  • The use of multiple reusable filters reduces the waste caused by disposable filters by up to 70 %.
  • Only wear-free magnetic couplings are used in the drive trains of Polyplan acoustic foaming systems. Their service life is about a factor of 10 longer than that of mechanical couplings and allow for sustained high-performance plant operation with high availability.
  • All potential main wear parts in Polyplan acoustic foaming systems are repairable. In the event of damage, they are not disposed of but replaced and reconditioned – which often more than doubles their service life. This avoids waste and ensures resource efficiency.
  • When shipping repair lines, Polyplan relies as far as possible on the use of reusable recyclable packaging – and thus avoids packaging waste to a considerable extent.
  • Almost all modules within Polyplan acoustic foaming systems are connected by durable, wear-free fixed piping. The absence of wear-prone hoses reduces the need for replacement during the system’s operating life and the amount of waste by around 30 %.
  • Polyplan has developed an innovative, non-destructive inline filling level control for the cavities of the acoustic foaming systems. It can replace manual and destructive quality control by up to 100 % and thus supports resource-efficient, sustainable and waste-avoiding process monitoring.
  • The use of new, energy-efficiency-optimised temperature control units for heating the PU components saves up to 20 % heating energy compared to other systems.
  • Dynamic temperature compensation, achieved through efficiency-optimised control of the pump speed, saves up to 10 % of the energy required for temperature control of the PU components.
  • All tanks, pipelines and heat exchangers in Polyplan acoustic foaming systems have efficient thermal insulation. The bottom line is that the insulation measures save up to 40 % of the heating energy required for system operation.
  • The “setback mode” for shorter downtimes, for example over weekends and holidays, reduces the energy consumption of Polyplan acoustic foaming plants by up to 30 %.
  • Compared to the proven HD-PUR 100 HR high-pressure unit, the new HD-PUR 100 UC high-pressure unit of the Polyplan acoustic foaming system has a reduced footprint of up to 80 %.
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