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Manufacturing Processes
IPS’ new manufacturing facility is located in Jackson, Miss. Our insulated metal panels are produced through a continuous, and virtually hands-free, fabrication process.
The line starts with painted coils loaded onto the coil cars. From there, the coil cars move the coils to the uncoilers. Next, the uncoilers move the coil into the roll formers and panel preheat, one for the top single-skin panel and one for the bottom.
After the panels have been preheated and roll formed, they move through the foaming process in which the foam is poured in liquid form onto the lower panel just before the lower and upper panel come together and pass through the double-belt laminator. The 104-foot laminator is the press that forms the insulated metal panels. Panel joinery side blocks move into place at the sides of the panel while it travels through the laminator. They come together to act as a side dam that prevents foam from escaping between the panel skins.
After the top and bottom panels are joined, they move to the automated panel saw where they are cut to the proper lengths, moved on an automated conveyor for panel flipping and cooling so the foam can cure, and placed on an automated cooling rack. Once the panels have cooled, they move on a conveyor to the bundle wrapper where the panels are packaged and sealed, ready to be shipped. The OSB base sets OSB board under the stack of completed panels before they are wrapped with a stretch-wrap film packaging. The foam cleat injector inserts pieces of cushioning at a right angle to the bundle so the bundles stay protected during storage and transportation.
With the technology of our new line, our ability to manufacture IMPs increases by more than four times compared to the process we used in the past. This provides us with the opportunity to meet the needs of our customers quickly and efficiently. |
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