Case study
Baulé® omega machines for large-scale cast elastomer parts
The bigger the cast PU part, the harder it is to ensure process reliability with reactive components. Our high-output Baulé® omega machines enable large-scale cast elastomer manufacturing. Precise metering and real-time monitoring ensure a consistent, homogenous mix for multi-ton elastomer parts.
EXSTO is a leading designer and manufacturer of high-performance polyurethane bend stiffeners and subsea protection solutions for the offshore and subsea energy industry, producing critical components weighing several tons while meeting demanding mechanical and durability requirements. These large-scale parts demand a high-output casting solution that delivers consistently high product quality and performance.
Baulé® cast elastomer machinery is our range of low-pressure dispensing equipment that is specifically engineered for PU elastomer molding. Process reliability drives the machine design, regardless of the chemicals used or the application field. Powerful electric heating maintains a constant temperature as the raw material mix is recirculated, ensuring even viscosity levels. Precise metering technology with real-time monitoring systems handle the mixing ratios and keep the chemical reaction sequences consistent. Degassing avoids air bubbles in the final mix. These features ensure polyurethane casting efficiency is optimized.
To support EXSTO's growing demand for large-scale bend stiffeners requiring exceptional process consistency and quality, Covestro developed a high-output casting solution based on its Baulé® technology.
Baulé® cast elastomer machinery is our range of low-pressure dispensing equipment that is specifically engineered for PU elastomer molding. Process reliability drives the machine design, regardless of the chemicals used or the application field. Powerful electric heating maintains a constant temperature as the raw material mix is recirculated, ensuring even viscosity levels. Precise metering technology with real-time monitoring systems handle the mixing ratios and keep the chemical reaction sequences consistent. Degassing avoids air bubbles in the final mix. These features ensure polyurethane casting efficiency is optimized.
To support EXSTO's growing demand for large-scale bend stiffeners requiring exceptional process consistency and quality, Covestro developed a high-output casting solution based on its Baulé® technology.
The larger the part, the more difficult is to ensure process reliability and consistent quality. Elastomer casting involves reactive liquids, and the homogenous mixing of the components despite the higher material volume is critical. Ratio mix must remain constant and stable at any production volumes, especially when reaching very high output such the ones required for large volume parts.
If the reaction fails in large parts that are mass produced, the amount of lost material can be considerable. Process failure carries a much higher cost than with small or low-volume parts. This is the technical challenge in large-scale offshore bend stiffener production.
If the reaction fails in large parts that are mass produced, the amount of lost material can be considerable. Process failure carries a much higher cost than with small or low-volume parts. This is the technical challenge in large-scale offshore bend stiffener production.
Our Baulé® omega machines give flexibility and reliability to manufacturers of large-scale cast elastomer parts. They help ensure that the reactive process and material mix remain consistent, avoiding high-stakes, costly process failure and lost material in high-volume production.
The Baulé® machine is tailor-made to deliver production consistency at high volumes, providing EXSTO an optimal casting solution enabling EXSTO to manufacture large and complex bend stiffeners with high repeatability, reduced process risk and consistent product performance.
Enlarged high-capacity storage tanks can hold several kilolitres with a specific agitation rate, and the mixing head is tuned to ensure ratio stability. Dedicated machine intelligence ramps up production precisely, while real-time monitoring systems keep the process consistent with homogenous dosing.
Our Baulé® omega machines can reliably deliver up to 2,000 kg of accurately mixed material every minute, enabling the processing of elastomer parts that weigh up to and over 5 tons. With Baulé® Easy Data, manufacturers like EXSTO can monitor the ongoing process, produce quality reports and analyze production trends in detail.
Enlarged high-capacity storage tanks can hold several kilolitres with a specific agitation rate, and the mixing head is tuned to ensure ratio stability. Dedicated machine intelligence ramps up production precisely, while real-time monitoring systems keep the process consistent with homogenous dosing.
Our Baulé® omega machines can reliably deliver up to 2,000 kg of accurately mixed material every minute, enabling the processing of elastomer parts that weigh up to and over 5 tons. With Baulé® Easy Data, manufacturers like EXSTO can monitor the ongoing process, produce quality reports and analyze production trends in detail.
Producing critical offshore polyurethane components at this scale requires both advanced manufacturing technology and extensive application expertise. The Baulé® omega solution supports our production process, while EXSTO's know-how in polyurethane formulation, process control and offshore applications enables us to consistently deliver high-performance bend stiffeners for our customers worldwide.
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Key benefits
- Process reliability: Material recirculation together with temperature and pressure regulation ensure consistency.
- Precise metering: With machine intelligence, production always ramps up with accurate dosing.
- Consistent mixing: Homogenous dosing means mixing remains consistent throughout production.
- Large-part capability: Tanks are adapted to allow for processing parts of over 5 tons.
- Accuracy at scale: Baulé® omega machines can output up to 2,000 kg per minute consistently at least.
