Finding the right balance between energy efficiency and cast PU manufacturing

Reassessing energy-intensive manufacturing to boost energy efficiency and ensure high quality

In its aim to make products and production climate-neutral, we have long implemented several measures that have helped the company cut its greenhouse gas emissions significantly and have, in fact, reached numerous milestones in overachieving our sustainability targets: as of 2023, the reduction reached -8.4% Scope 1 and Scope 2 and -27.8% Scope 3¹. Despite this, it is clear that we cannot rest on past laurels. Sustainability and climate neutrality are vital to our own future and the future of our planet. 

As part of our commitment to improve constantly, our ambition to provide state-of-the-art solutions that enhance energy efficiency and reduce consumption and costs is an important step forward. In this regard, the focus on reassessing and boosting efficiency in the particularly demanding and energy-intensive manufacturing processes associated with cast polyurethane products is obvious. 

Yet, despite its expertise and innovative approaches in reducing energy consumption and costs, we are aware that this is not enough. Enhanced manufacturing processes and solutions that ensure finished cast polyurethane products fulfill the high demands for their intended applications in terms of durability, performance and quality are equally vital. 

Deliver efficient solutions

Across a wide range of industries – from agriculture, construction and earthmoving operations, mining, oil and gas supply, and wind energy to packaging, sports and leisure – the most durable materials are required to produce high-quality components and equipment that can be exposed to the toughest environments and withstand extreme conditions. Building on decades of experience in material science, our cast polyurethane products play a vital role in delivering state-of-the-art solutions. 

The manufacture of cast polyurethane elastomers is, however, energy-intensive. Each step in the manufacturing process – for example, component preheating, component processing temperature, mold heating, curing and post-curing – involves high energy consumption. Often, these steps also involve additional energy-consuming aspects such as separate ovens, heating tables and dispensing machines. 

We are committed to interacting responsibly with raw materials and energy and leading the way in reducing the impact on the environment. 

Ensure consistent performance and productivity

Delivering the mechanical properties of the finished cast polyurethane product according to specifications is a must. Reducing energy consumption in the manufacturing process is a challenge. Energy management, low-energy systems, smart metering and temperature control of the relevant materials through every step in the process are key in successfully achieving the expected chemical reaction. 

Although adjusting the temperature of the component itself is difficult, it is possible to adjust certain parameters in order to optimize energy consumption, in particular the temperature of the mold, and subsequently the curing and post-curing phases. 

Decades of research and solutions in cast polyurethane chemistry have led to a unique range of versatile energy management systems and machines with multiple configurations, scalability options and peripherals that cater to the various process requirements of our customers, often also enhancing flexibility and capacities. 

Our Baulé® machines, for instance, are the product of the company’s in-depth expertise in molding, its know-how of polyurethane chemistry and elastomers, and the integration of efficient tools and technology in the production of cast polyurethane parts. 

From their inception, Baulé® machines have been designed to consume as little energy as possible. One of the striking features is, for example, an efficient electrical heating system that allows for the independent regulation of equipment and components, thereby also ensuring easy adjustments and constant temperature of the products. In addition to minimizing energy consumption, Baulé® machines offer several advantages in terms of maintenance, reliability and user-friendliness. 

Product properties and manufacturing processes

The impact of temperature fluctuations – and, consequently, of temperature control – on the properties of the finished product cannot be ignored and represent one among many challenges in cast polyurethane manufacturing. Our experts worked on the formulations to compensate the impact of temperature effects in order to optimize the balance between processes and the product’s mechanical properties. 

We offer enhanced formulations, technologies and systems that are easy to integrate into existing cast polyurethane manufacturing processes without having a major impact on characteristics such as viscosity, pot life and green strength. 

As a global player, we thus continues to set new standards by integrating innovative and efficient technologies. Not only does this signify a contribution towards lowering energy consumption and associated production costs but, as a consequence, also offers a path customers can take to reduce their reliance on fossil-based energy. 

Energy consumption tool

Enhancing the manufacturing process to offer a balance between energy consumption reduction and maintaining optimal mechanical properties was the first step. To estimate the benefit in terms of energy and costs savings for the moulder, it was mandatory to quantify them.

In this regard, the process condition modifications allow moulders to reduce by up to 60% their energy consumption. Furthermore, as each molder is a specific case, a tool was specifically developed: customers can enter their own processing data and energy price to estimate their energy savings.