Sheet casting
Sheet casting
High performance sheet casting solutions
IPCO is a world-class supplier of industrial process solutions with extensive experience in sheet casting technology. In 1901, we produced the world’s first steel conveyor belt and have been supplying steel belt-based industrial processing systems for over 90 years.
Our continuous sheet casting equipment was initially developed for resin based composite material. It is now used around the world for the continuous production of solid surfaces, engineered stone, and other compound-based products.
Modular systems for continuous sheet production
We pioneered the use of steel belt lines for the continuous cast sheet belt production of resin-based composite materials and continue to lead the way in casting systems for an almost unlimited range of compounds.
Our modular approach to system design means we can combine different types of processes into one continuous production process. This multi-stage approach, incorporating controlled polymerization, curing and cooling in a single system, enables the development of highly efficient, environmentally-friendly process solutions.
The key advantages of this modular design approach include:
Precise heat profiles via multi-staged zones
Heating, reaction, calibration, cooling and confection in one in-line process
High productivity
Adjustment of process profiles for different cast sheet products
High accuracy and superior surface quality
Variation of product width and thickness for resin based material and a wide range of other compounds
Sheet casting
Experience
1935
First industrial processing system
Global support
80+
Service technicians across more than 25 countries
Efficient
1
Single system, multiple processes – a range of flexible casting solutions
How it works
Our solutions
The versatility of our system design: the ability to tailor each separate stage of production to specific product requirements – enables us to provide custom casting solutions for virtually any requirement using a range of casting solutions components.
We can also integrate up- and downstream equipment, including metering, dosing, and mixing equipment, unwinding/rewinding, and cutting/stacking equipment for a range of flexible casting solutions.
Multi-zone design for continuous sheet belt production
After dosing and mixing, the compound product is cast on the continuous sheet belt and calibrated to the required width and thickness. From here it passes through precisely controlled heating, polymerization, and cooling zones. This is followed by hardening/curing, and finally a second cooling stage for the cast sheets.
After discharge from the belt sheet casting system, the sheet is cut into tiles, ready for any additional finishing processes.
Single and double belt sheet casting
Systems are available in the form of single or double belt casting units to meet different process needs.
Single belt sheet casting units
Versatile – variable product thickness
Economical continuous production
Double belt sheet casting units
Versatile – adjustable product width
Narrow thickness tolerance
Smooth, high quality product surface
Highly efficient with symmetric heating and cooling
Minimal release of solvents for environmental protection
Benefits
Why choose IPCO for your custom cast solutions
Highly efficient continuous production
Steel belts for strength, durability and excellent return on investment
Low tolerances on film/sheet thickness
High clarity and low stress in the formed product
Perfect surface properties using IPCO mirror-polished steel belts
Thick slab products are possible
Multiple process zones on the same machine
Complete polymerization
Portfolio showcase
Delivered by our solutions
Chocolate forming systems
IPCO’s chocolate moulding systems enable cost-effective production of high quality industrial and decorative chocolate products.
Cooling systems
IPCO’s cooling lines combine steel belts with highly efficient air and/or water cooling systems to deliver rapid, controlled solidification.
Drying systems
IPCO’s dehydration systems enable quick, hygienic, and energy efficient drying of wide range of fruit and vegetables.
Drum granulation systems
We offer the highest capacity units available to produce formed sulphur to SUDIC specifications, embodying the best of granulation technology.
Double belt presses
IPCO’s modular double belt presses can seamlessly integrate numerous processes into one continuous system, for efficient production at scale.
Extrusion systems
IPCO’s high-performance twin-screw extruders combine outstanding throughput rates with easy access for rapid product changes.
Freezing systems
IPCO’s steel belt-based freezing systems deliver rapid freezing, maximum hygiene, and consistently high product quality.
Material handling
Our bulk material handling solutions encompass everything from conveyors and elevators to storage and loading systems.
Oil skimmer conveyor
IPCO’s oil skimmers use steel belt technology to enable quick, continuous, and effective extraction of oil from water.
Powder coating forming systems
Transform raw mixes into perfectly cooled flakes ready for milling. Harness our unparalleled expertise in cooling, flaking, and extrusion to achieve the flawless finish you envision, time after time.
Rotoform systems
IPCO’s Rotoform technology handles pastillation with ease and precision, from complex chemicals to food.
Scattering systems
IPCO’s oscillating and rotating brush-off systems deliver versatile and precise scattering for powders, granules, fibers, chips, flakes, and other materials.
Steel belts
Since 1901, our steel belts have been the backbone of industrial efficiency, driving reliability and performance in every process we’re part of.
Spray systems
Innovative design allied with precision engineering to achieve dramatic improvements in the application of release agents onto press belts.
Thin film casting systems
IPCO’s high precision thin film casting systems enable the production of film products to exceptionally narrow tolerances.
Venturi dryer
Effortlessly evaporate solvents and perfect your film casting process with our innovative, tension-free drying technology.
Engage
Explore IPCO
Industries
We use our expertise in each industry to design cutting-edge production equipment that meets our customers’ needs.
Processes
We make industrial processes smoother and more efficient, for today and tomorrow.
Solutions
We create innovative solutions that reliably deliver our customers’ productivity goals.
Service and support
Our global presence ensures that no matter where you are, your manufacturing technology can keep performing at its best, thanks to top-tier service and expertise locally.
Get in touch
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