K.R.Enterprises Aluminium Composite Panel
 
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Overview:-
The manufacturing line consists of the Extrusion Section, where the PE is mixed , melted extruded with advanced control systems for consistent quality. The Extruding Head controls the volume of the PE core and you can adjust the thickness of the board precisely as per the batch requirement.

The Extruded PE board then goes to the Rolling Press section, where pressing with the latest technology makes it a flexible yet powerful plastic board with perfectly smooth and flat surface. The pressed board then passes to the Adhesive Film Compound Section where the special adhesive film is applied to the lower and upper sides of the PE board, to pass on to the Aluminium Coil Frame Section.

At this section, the top and bottom Aluminium Coils are placed on the PE board, to pass on to the Aluminium Coil Frame Section. At this section, the top and bottom Aluminium coils are placed on the PE board through a constant tension control system and the board with top and bottom Aluminium coils passes on to the Compounding section , where a oil heating circle system fuses the Aluminium coils to the board at a high temperature.

Next the PE board fused with Aluminium coil passes through a flattening roll and air cooling systems producing finished ACP. The finished panels then goes to the Protective Film Compounding Section. The Automated Trimming section then cuts and trims the panels in to the required size. The entire manufacturing process is automated and ensures the highest quality by eliminating the possibility of human error.

Manufactured on fully automatic plant.
An ISO 9001:2000 certified company.
Production facilities with daily production capacity of 50,000 sq ft.
Three roller high techniques incorporated for excellent flatness, smooth surface & high bonding strength.
Frequency controlled variable AC drive to ensure uniform speed of extruder
Desired uniform extruded output ensured by Professional Integrated Derivative (PID) controllers for temperature control of Extruder Barrel & ‘T’ dies.
Well equipped testing laboratory.
Closed circuit roller-cooling & air cooling to reduce & / or avoid building of any stresses.
 
Features:-
 
Manufactured on fully automatic plant.
Right Choice of Adhesive
Top Aluminium coil - store lacquered with weather-resistant PVDF (70%) base coat
Aluminum coils coated in latest hi-tech European plant.
High peeling strength
ACP with its tough 'anti-impact and anti -scratch properties is not damaged even in strong storms or sandy conditions.
Has excellent sound and thermal insulation properties.
 
Class Apart:-
 
Following facts make Aluminium Composite Panel a Class Apart:-
 
The Key Coating Component
   
KYNAR 500® resin- a fluoro- polymer with remarkable bonding properties of its molecular structure- the carbon/fluorine bond (one of the strongest bond)
   
Life expectancy of 20 yrs of PVDF coating.
   
Adhesion
   
The perfect bonding between the Aluminium coil & core achieved by using adhesive film manufactured from raw material sourced from DUPONT USA.
   
The highest quality bonding ensures:
     
Avoids de-bonding & bubbling  
     
Core material  
     
Improved binding strength.  
   
High Acoustic Value.
   
Non Brittle central core
   
Heat Resistance
   
Protective Film
   
ACP is covered by a protective film.
     
Application of the film during manufacturing process protects the plain top coated surface while handling, fabrication & installation.
 
Handling& Storage
 
Storage

1.
Always store ACP horizontally face to face & back to back on the pallet to prevent bending or warping.
 
2.
Group panels to be placed according to thickness and colour, when storing to avoid unnecessary handling.
 
3.
Store away from rain, dripping water and other environmental hazards.

Maintenance 
To remove soil and dirt, wipe with water, applying moderate pressure. If necessary, a mild detergent solution can be used. Never use paint removers, acids, thinners, scrubbers or sharp metals for cleaning.

Protective Film
The protective film should be removed within 45 days of installation at the maximum to avoid any damage or contamination by the surface bonding material.

 
Drilling  

Always use drill bits for aluminium sheets and plastic panels. For larger holes use a drill bit with a locating point.
Routing  
Conventional routing equipment can be used. Plastic or wood vice jaws should be used to avoid pressure marks when chucking the work pieces.
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Shearing  
Can be done with a guillotine. All blanking tools should be padded to avoid marks.
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Bending  
  
Can be bent to inside bending radius r = 15 x t (panel thickness), with the help of a folding table.
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Screwing  
Conventional stainless steel, wooden, sheet metal or metal screws should be used. For external use, panel expansion should be taken into consideration.
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Folding (by routing)  
Can be done manually after routing a V-groove on reverse side with a panel saw with milling attachment or hand-milling cutter.
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Edge Smoothing  
Use file with rasp like cut, to file any roughly cut corners.
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Pressing  
Use brake press for min. inside radius r = 15 x t (panel thickness)
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Punching  
A steel band tool on a punching base should be used for panels of 2 to 3 mm thickness. Or conventional sheet punching machines for any thickness.
 
Class apart:-

Following facts make a Class Apart:-

       The Key Coating Component

  •  KYNAR 500® resin-   a fluoro- polymer with remarkable bonding properties of its molecular structure- the carbon/fluorine bond (one of the strongest bond)

  • Life expectancy of 20 yrs of PVDF coating.

  • PVDF coating NOT adversely affected by environmental hazards

 

Adhesion

  • The perfect bonding between the Aluminium coil & core  achieved by using adhesive film manufactured from raw material sourced from DUPONT USA.

      The highest quality bonding ensures:

  • Perfect peel off strength

  •  Avoids de-bonding & bubbling

      The highest quality bonding ensures:

  • Perfect peel off strength

  • Avoids de-bonding & bubbling

 

Core material

  • Improved binding strength.

  • High Acoustic Value.

  • Non Brittle central core

  • Heat Resistance

      Protective Film

  • ACP  is covered by a protective film.

Application of the film during manufacturing process protects the plain top coated surface while handling, fabrication & installation.

Specifications
 
STANDARD DIMENSIONS OF ACP

Width : 1220mm (1550mm optional)
Length : 2440 mm,3050 mm, 3660 mm (up to 6100 mm optional)

Standard dimensions and Thickness available:

• 2 mm : PE
• 2 mm : PE
3 mm : PE
3 mm : PVDF
4 mm : PVDF

 
Production Tolerance:
A. Width: ± 2.0 mm
B. Length : ± 4.0 mm
C. Thickness: ± 0.2 mm
D. Bow : ± 0.5% Length or width
E. Square ness : Maximum 5.0 mm

THE FOLLOWING TESTS ARE CONDUCTED AT OUR IN-HOUSE TEST CENTRE:
• Thickness Of ACP Panel
• Thickness of Aluminium coil
• Thickness of Paint Coating (PVDF)
• Gloss Test
• Colour Matching in Repeat Orders of Coil
• Humidity test for weather ability
• Hot Air Oven Test
• Salt Spray Test
• Peel Off strength
• Flexural Strength
• Shearing Strength
• Ball Drop
• Bending Strength of PE board and Panel
• Acid Test & Solvent
• Pencil Hardness

TECHNICAL DETAILS FOR RANGE OF PRODUCTS (FOR EXTERIOR APPLICATION ONLY)
1. PHYSICAL PROPERTIES  
Item
Standard  
Remarks
Panel thickness
 
3 mm, 4 mm
 
Panel thickness 6 mm are available on request
Aluminium cover sheets thickness (Skin)
 
0.25 mm, 0.5 mm
 
Non-standard thickness can be available on request
Core
 
The thermoplastic core LDPE +HDPE
 
The thermoplastic core in panel is a mixture of LDPE & HDPE and non-toxic in nature.
Panel Width
 
1220 mm, 1550 mm
 
Also can be made to customer specification.
Panel Weight Surface
5.48/m2 ± 7% Exterior face coil coated with PVDF (KYNAR 500, min 70%).
 
 
Mechanical Properties
ACP is light weight but rigid material. It resists to blows, breakage and high wind pressure  and has bending, buckling and breaking strength. The mechanical properties of ACP are as follows (panel thickness 3 mm & 4 mm, skin thickness 0.25 mm & 0.50 mm respectively) :
 
Item
Unit
Test
 
Standards
 

3 mm

 

4 mm

 
Specific Gravity
 
g/cc
 
1.38
 
1.52
 
Tensile Strength
 
mpa
 
45.8
 
48
 
ASTM D 638
Yield Strength
 
mpa
 
43.4
 
44.2
 
ASTM D 638
Flexural Rigidity
 
X105 Kg.mm2
 
7.3
 
14.0
 
ASTM C-393 (20 cm span)
Elongation:
 
 
 
Horizontal Elongation at breaking point
 
%
 
12 %
 
14 %
 
ASTM E-D 638
Vertical Elongation at breaking point
 
%
 
11 %
 
13 %
 
ASTM E-D 638
 
Application
 
You can use ACP on practically every surface. Its beauty and aesthetics will allow you to give full rein to your imagination. Bend it, curve it, make shapes and colorful patterns by choosing panels of different colors. You can use it on the widest range of surfaces:
 
Exterior as well as interior walls of buildings and structures.
   
Decorative strengthening additions when renovating old buildings.
   
Ceilings, bathrooms, kitchens, balconies.
   
Petrol Pumps.
   
Shop door decorations.
   
Hoardings, display platforms, Signboards.
   
Interior of tunnels.
   
Structural glazing of high rise buildings.
   
Automobile industry.
 


 
 
 
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