Cold Storage PIR Sandwich Panel Line in Saudi Arabia

Illustration notice. Process illustrations are not verified photographs of this installation.

Project reference basis. Figures and configuration details are reported in the supplied project brief. They are reference values for the stated application, rather than verified acceptance results or a guarantee for another installation. Confirm the source records, material, tooling, operating schedule and test method when assessing a comparable project.

Concept illustration — not a photograph of delivered equipment or a customer installation.

Project figures below are reference values from the supplied project brief. They describe this configuration and are not certified results or guarantees for other projects.

Haifeng successfully engineered and commissioned a heavy-duty continuous PIR cold storage sandwich panel production line for a premier refrigeration contractor in Saudi Arabia, enabling local mass production of 200mm thick deep-freeze panels with a reported reference thermal conductivity of λ ≤ 0.020 W/(m·K). The turnkey delivery included deep-step roll forming units, a high-pressure pentane-blown PIR metering station, an extended 36-meter continuous heated double-belt laminator, an automated synchronous flying cutter, and automatic pallet packaging equipment.

Prior to commissioning, the customer struggled with extreme climatic challenges. With Saudi desert ambient temperatures exceeding 50°C and cold storage interiors held at -30°C, the resulting 80°C thermal gradient caused conventional panels to warp, shrink, and leak frost at joint seams. The client required an advanced continuous manufacturing architecture capable of processing high-index polyisocyanurate formulations, controlling core exotherms across 150mm–200mm thick profiles, and precision roll-forming deep labyrinth tongue-and-groove joints to stop thermal bypassing.

Operating on a continuous two-shift daily schedule across a 2,200 m² facility, the production plant outputs over 2,500 m² of heavy insulation panels per shift. By integrating Haifeng's closed-loop Ratio Lock chemical dosing and heavy-rigidity 36m double-belt lamination, the client manufactures energy-efficient cold room panels that cut facility cooling power losses by 35%.

Project Technical Specification Matrix:

Planning a related production line

For a new cold-chain project, distinguish factory-made panel production from on-site insulation spraying. Confirm the material system, envelope or panel design, production/installation target and acceptance conditions before transferring any project setting.

Production brief for technical discussion

Provide a finished-product drawing or sample, material data, target output, automation needs and factory conditions. Haifeng will review the process, equipment interfaces and acceptance plan for your own production goals.

Area output per shift is a supplied project reference. Effective width, shift duration, running time, changeovers and accepted-panel yield must be specified before deriving or comparing area capacity.

Haifeng deployed an industrial continuous double-belt production platform engineered specifically for thick-core, high-density polyisocyanurate insulation panels, achieving controlled thermal barriers across long operational cycles:

1. Deep-Profile Labyrinth Roll Forming: Roll forming cassettes cold-roll pre-painted steel sheets into deep multi-step tongue-and-groove profiles, creating tight mechanical interlocks that support joint sealing.
2. Pentane-Safe High-Pressure Dosing: An explosion-proof chemical dosing skid delivers pentane-blown polyol and isocyanate at up to 200 bar, distributing the stream via a servo-driven oscillating nozzle for complete surface wetting.
3. Heavy-Duty 36m Heated Double Belt: An extended 36-meter heated caterpillar laminator provides prolonged, uniform pressure at 65°C, with cure and core-temperature settings selected for the stated 200 mm panel reference.
4. Synchronous Deep-Section Flying Cut: A heavy-duty disc cutter moves synchronously with the panel, cutting through 200mm profiles with ±2.0mm accuracy without halting the continuous line.