KPS Global® is the industry-leading manufacturer of insulated panel systems used in walk-in coolers, freezers, scientific chambers, refrigerated warehouses and more. We fabricate all of our panels to the exact specifications of customer-approved submittal drawings, including dimensions, panel type, finish, type and location of doors and all accessory items.
We manufacture cam-lock panels, which lock together with the use cam and pin housing assemblies. Each individual cam-lock panel includes one of three perimeter framing materials that is covered by a metal interior and exterior skin that is then injected with polyurethane foam.
Here’s a closer look at the manufacturing process.
Frame Prep
The fabrication process begins with coils of metal that are cut into lengths based on project specifications. The metal is fed through a roll former, which is a machine that rolls the edges of the metal up one-half of an inch at a 90-degree angle, and then corners are notched out, forming a metal pan, or one side of the panel.
At the same time, framing materials (wood, high density urethane, or FUSIONFRAME®) are fed through a profiling machine, which creates the tongue and grove profiles. A mortise line creates a slot for the cam-lock and pin assemblies to be securely joined together.
The frame is placed in the metal pan with an overlay of the remaining piece of metal, creating a hollow panel. Hollow panels go through a series of quality checks to ensure that they were created correctly. Once the panel has been approved by an operator, team lead or supervisor, and quality control inspector, the panel moves to the foaming stage.
Foam Injection
Hollow panels are placed on heated platens in our multi-tiered sandwich press. Computer-controlled foam guns inject a precise amount of liquid polyurethane insulation into the panel, depending on specified individual panel thickness, length and desired R-value. Different panel thicknesses require different cure times; this calculation is determined by engineers before the manufacturing process occurs.
When the foam is injected, a chemical reaction occurs, which causes the foam to expand under the controlled conditions. It amalgamates the individual components, forming a single, structured panel.
The panels remain in the presses between 45 and 70 minutes to allow the polyurethane foam to cure and stabilize before being removed for final inspection and shipment.
Final Assembly
Once they are removed from the panel press, panels are checked for cleanliness and excess foam is removed.
Next, any trim or accessories are installed, including light switches, air vents, thermometers and gaskets.
Once these components are installed, completed panels are prepared for shipping by being stacked and then processed through an orbital wrapper. The material that secures the panels in place is a UV-protected film.
Wrapped and completed panels are marked and ready for shipment.
Check out the video below for a virtual tour of one of our manufacturing plants.
Contact us today to place an order for a custom walk-in today!
