Polyurethane
casting line
Equipment for continuous metering and mixing of polyurethane components with mineral fillers and microspheres.
Bolshevik industrial area, Razbegaevo, Lomonosovsky district, Leningrad Oblast 188513, Russia
Phone +7 (921) 782-00-00 · sales@polyblender.ru · polyblender.ru
Contents
The line
Polyurethane is becoming the new benchmark in filled composites: the market for polyurethane products is the youngest and the least exploited of the four systems.
The line is built from current-generation components. Motors and geared motors by Siemens (Germany). A patented high-speed low-pressure mixing head of our own design mixes the liquid polyurethane components at an infinitely variable speed up to 6000 rpm.
The metering screw is made from high-grade alloy steel with a bimetal-tungsten coating. Feeders for coarse and fine filler carry an active dynamic bridge-breaking device that prevents the material sticking or hanging up in the screw zone.
The glass microsphere hopper uses a purpose-designed feed screw so that spheres are charged dust-free through a diaphragm pump built for powders. A separate feed unit handles Expancel polymer microspheres, with patented blades that fluidise the powder for trouble-free transport and accurate metering.
Unlike polyester systems, polyurethane emits no styrene: post-curing chambers and warehouse dwell time drop out of the cycle and workshop ventilation requirements are lower.
Units of the line
Dry component metering
Feeders for coarse and fine filler with a metering screw. The active dynamic bridge-breaking device prevents the material sticking or hanging up in the screw zone.
- WIKA level sensors (Germany)
- Replaceable filter cartridge on each feeder
- Siemens geared motors (Germany)
- 2 aeromechanical conveyors for automatic loading, stainless steel
Liquid component metering
Metering of liquid components of any type has to be highly accurate. Components are delivered by dedicated pumps and valves and switch to recirculation automatically when the machine stops.
- Polyol buffer tank approx. 180 l, stainless steel, with agitator and level sensor
- Separate isocyanate tank approx. 180 l
- Component thermostatting
- Ultrasonic level sensors
- High-accuracy metering pumps, ratio range 2:1 to 1:2
Microsphere metering
An ATEX-rated feeder for Expancel microspheres handles the light filler. Filler is delivered to the casting machine through hoses, dust-free.
- Metering pump
- Storage container with filter
- Valve, pressure regulator, fittings
- Electrical control
- ARO powder diaphragm pump (USA) with automatic pulse valve purging
- Manual and automatic loading from the operator panel
Liquid component mixer
A dynamic pre-mixer for intensive mixing of the liquid components by an electrically driven screw mixer, with valves for the liquid components and for cleaning agents or solvents.
- Low-pressure mixing head, infinitely variable to 6000 rpm
- Automatic and manual solvent flushing with air purge
- Horizontal traverse carriage for calibration and servicing
- 2.2 kW paddle polyol agitator with decentralised inverter
- Automatic start at a set time before charging the main tank
Mixing and casting unit
Mixer in special steel producing low transverse load, with a wear-resistant agitator and bimetal-tungsten coating. The balanced cantilever mixing screw runs in a ball bearing support. The line, including the casting unit, is carried on a steel frame.
- Automatic casting: two ARO diaphragm pumps (USA)
- Optical and ultrasonic level sensors
- Hose set, 4 m
- Colour feed unit with agitator and tank heating
- High-accuracy metering by FESTO servo drive (Germany)
Vacuum system
An integrated vacuum system for continuous degassing of the casting mix during production.
- Residual pressure 0.1 mbar
- Vacuum degassing column
- Vacuum sensor and vacuum gauge
- Chemically resistant seals
Compressed air supply
The system governs valve operation and the delivery of cleaning agents or solvents, and performs automatic process control if pressure drops sharply below the set point. Compressed air — dry, cooled and free of oil — is delivered locally through a flexible line.
- FESTO pneumatics and hoses (Germany)
- Automatic response to pressure drop
Line control system
A separate electrical distribution cabinet carrying the whole control and monitoring system plus a frequency converter for each metered component, connected to the casting line by a 5 m control cable.
- 12″ touch panel: casting output, recipes, fault messages
- Process diagram with processing and equipment control data
- Remote control module over WIFI
- Siemens electronics
Applications
Decorative wall panels, boards with full wood-pore imitation, engineering tooling boards, soft products with a polyurethane decorative skin, cast stone articles, kitchen worktops and sinks, stone slabs, floor and façade panels with marble, onyx and travertine imitation, bonded abrasive wheels for the jewellery, glass and woodworking industries.
The base configuration already covers a broad range of applications. Unit layout, output and degree of automation follow the customer's technical specification: the VAC-2/15 base line has a public price list (polyblender.ru/konfigurator/), while custom builds are quoted once the specification is agreed.
We also build lines for two-component acrylic (PMMA) and epoxy (EP) resins with mineral fillers and vacuum degassing. The machine design is shared across all four binder systems; what changes is the configuration for the binder.
SARMATECH LLC · TIN 4725011864 · PSRN 1214700012890
Bolshevik industrial area, Razbegaevo, Lomonosovsky district, Leningrad Oblast 188513, Russia
Phone +7 (921) 782-00-00 · sales@polyblender.ru · polyblender.ru
Catalogue current as of September 2026. The manufacturer reserves the right to alter the design and configuration.
Printed catalogue
Full illustrated catalogue with photographs of every unit: PDF 28 MB, 13 pages, with a text layer. The printed edition is in Russian; this page is its English equivalent.
Download PDF (28 MB) ↓ · Machine-readable version (Markdown) ↓ · ← Back to the line · Русская версия