Opus Special Projects
Opus Special Projects (OSP) provides an experienced engineering solution for todays changing foam production requirements.
From a development project, modification to an existing machine or complete new build, Opus has the skills and experience to deliver a tailor made solution at an affordable price.
Opus is the World’s only experienced provider of this service with over 50 years in the PU business and globally respected design and technology.
Detailed engineering and technology support
Equipment Design
Complete Project Management
Installation and Commissioning
Engineering Services
1
Design
Opus Technical’s team of experienced Engineers work with the Customer to understand the requirements of the project and design a tailor made solution.​
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Our in depth knowledge of flow, pressure and thermodynamics allows us to provide fully engineered, working designs.
We work with the latest instrumentation and control systems and provide functional design specifications as well as integrated software and data acquisition packages.
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Opus is unique in being able to provide a comprehensive package from initial design to finished operating systems.
2
Manufacture
Once we have completed the design process we manufacture your machine in our state of the art factory here in the UK.
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We have a strong network of suppliers who can provide us with the parts needed to manufacture your machine, using only the highest quality materials.
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Our team of experienced engineers will take drawings from the design process and bring them to life, ready for installation into your factory.
3
Installation
Once manufacture is completed here in the UK we will ship the machine and equipment straight to your factory. We ship to a worldwide customer base; no distance is too far.
Once everything has arrived on site, we will send Opus Technical Engineers over to manage the installation and commissioning of the machine. We will train your staff to operate the machine upon completion of the installation process.
Once everything is set up and running smoothly we will offer technical support for any queries or issues that may arise.
OSP Case Studies
Dual Zone Mixing Head
Portugal
Customer Requirement: To improve mixing of ultra low output colour on a high pressure mixing head whilst maintaining excellent cell structure. OSP Solution: To design and supply a unique dual zone mixing head addition that would fit onto the Customers existing mixing head structure and pipework system. This unique mixing system gives a high shear section to efficiently mix the ultra low output colour whilst separating out the high pressure injection of TDI and so maintaining the cell structure.
Silicon/Air Pre Mixer
Portugal
Customer Requirement: To improve cell structure of the foam and reduce pin holes OSP Solution: To design and supply a special pre-mixer for Silicone and Air. The specially designed Opus High Shear mixing unit combines both rotary and static mixing which efficiently breaks down the nucleating gas bubbles and mixes them uniformly. The Opus Silicone/Air Pre-mixer can be fitted to any existing Slabstock Machine to improve the cell structure control and reduce the amount of pin holes associated with the traditional method of introducing air directly into the polyol stream or Mixing Head. It is compact, easy to install and fits into the silicone stream before or after the recirculation valve. It can be mounted vertically or horizontally. The unit is complete and includes: - Fixed or Variable Speed AC drive, 3000 rpm - Port Ring - Lubricated seal housing - Barrel - Stirrer - Mounting plate - Outlet pressure control valve Nucleating air or Nitrogen is added via a specially designed nozzle and can be controlled either by manual needle valve or thermal mass flowmeter.
Round Block Conveyor
USA
Customer Requirement: To replace a very old, high waste 48inch round block conveyor with a new high yield 50 inch system during a 2 week Christmas/New Year shut down. OSP Solution: to design and supply a new, heavy duty 50 inch diameter, 3 section conveyor system to fit into the existing equipment footprint and to guarantee completion in a 2 week shut-down. From initial concept design discussions to complete project management, Opus worked round the clock through a challenging shut-down to deliver equipment that exceeded the Customer expectations.
MDI Graphite Metering
Ireland
Customer Requirement: To integrate a new high pressure MDI-Graphite slabstock chemical system onto an existing low pressure Maxfoam machine. OSP Solution: In conjunction with both the Customer and raw material supplier to design and supply a new 4 stream high pressure metering system and Graphite powder/polyol blend system. Then to integrate this into the existing foaming line and control system. From initial concept design discussions with both the Customer and raw material supplier Opus supplied a complete system including metering, mixing and control. We also supplied the bulk tank farm, pipework and temperature control system.
Drill and Foam in Place
UK
Customer Requirement: To provide a complete line to insulate the core of an extruded plastic profile for the construction industry with a rigid PUR Foam OSP Solution: To develop a production line to handle, drill and foam in place the extruded hollow section and to provide a high pressure 2 component rigid PUR dispensing machine. Opus designed a multi position drilling and foaming line together with a foaming press and handling system to infeed the sections and outfeed the finished units.
Planiblock Flat Top System
Mexico & Portugal
Customer Requirement: To add a Planiblock Flat Top System to an existing high Pressure Liquid Laydown Ultima Slabstock machine to improve block yield. OSP Solution: To design a modular Planiblock unit that could be installed onto the existing machine with minimum interruption to production. Opus designed an 8 ski adjustable width Planiblock unit complete with top paper infeed and rewind units that was successfully installed onto the foaming machine without interrupting production.
RS Flat Top System
UK
Customer Requirement: To provide a state-of-the-art fully automatic and remotely controlled RS flat top system for 2 VPF slabstock machines OSP Solution: To study the existing RS specification and re-design it so each aspect of the equipment including all speeds, positional indication, angle and movement is fully controlled and operating parameters can be monitored and stored by a computer controlled system . Opus built 2 fully automatic units which were supplied and fitted inside the VPF enclosures.
Liquid Laydown Fallplate
USA
Customer Requirement: To replace an existing Trough/Fallplate System with a liquid laydown Fallplate unit to improve cell structure. OSP Solution: To design and new fully automatic Pour-Plate/8 section Fallplate and liquid laydown mixing head and laydown system to integrate into the existing conveyor system. Opus’ well proven Ultima system is a high specification unit which combines a liquid laydown pour-plate with an 8 section Fallplate, allowing both liquid laydown and trough laydown on the same machine.