Alu Bender Photo Eng

A new and revolutionary process of composite panels for
Visual Communication
© SAMEC S.p.a. - Republic of San Marino - 2014 1

A good Presentation of our technology requires some
explanations…
Let us talk a bit about the Boards for
Visual Communication:
-Past and Present
-Pros and Cons
-Ways to process them
2© SAMEC S.p.a. - Republic of San Marino - 2014

Actual boards used into Visual Communication
•Alu composite panels (Dibond®, Alucobond®)
•Paper honeycomb boards (Reboard®, Xanita®, Falconboard®)
•PVC-foam composite boards (Kapamount®, Egafix®, Encore®)
Boards used in the past
•Solid 2 mm alu boards
•Solid 1 mm steel sheets
•Compact PVC (Forex)
•Carton boards

Why boards from the past are not interesting?
•They are not flat
•They are heavy
•They are not cheap
•They easily flex after laminating, printing or UV coating
Nowadays composite boards are…
•Flat and light
•Cheap but valuable and durable
•Easily 100% recyclable
•Strong enough to resist laminating and UV coating

This is all clear and the offer of these boards is growing
everyday…
So, what can Casadei Industria offer?
Just a moment…
What are the processes available for these boards?

Easy answers:
•Digital Printing (direct print)
•Lamination (apply of pics and transparent films)
•UV coating
•Routing (flute tools and oscillating knifes)
•Straight cuts (circular saw and knife cuts)

What is common between all these processes?
THEY ALL ARE ABOUT THE “SURFACES”
Next question is also easy…
WHAT ABOUT THE “EDGES”?

WE, at Casadei Industria, take into serious
consideration edge banding of panels…
After 20 years and 20.000 machines produced, for the
woodworking industry, we feel to be the right
“answer” to the question about the “Edges” on Visual
Communication boards.

CASADEI INDUSTRIA is proud
to introduce…

Alu Bender Photo
Finishing machine for EDGES of boards for Visual
Communication

Alu Bender Photo
This video explains how it works… click on the
link.
Alu Bender Photo Video
http://goo.gl/vT045N

Alu Bender Photo
The process in details:
-automatic feeding
-horizontal and vertical pre-cut
-milling off the remaining excess
-creasing wheel
-glue gun
-bending rollers
-holding and cooling device

Alu Bender Photo
Automatic feeding
Is the “core function” that allows
a perfectly straight feeding
without damaging both faces of
the board.
14
It is made of a chain with rubber and plastic pads. A line of rubber rollers over the chain
allows a smooth pressure that determines the feeding.
Rollers are adjustable with handle and numerical indicator.
The motor for feeding is threephase with 0,73 Kw power.
The speed is variable between 2 to 8 mt/min controlled by the PLC.
As it is installed on all our machinery for wood working, this unit is fully proven and reliable.
The big surfaces of rubber allow good holding and no signs on the surfaces.
© SAMEC S.p.a. - Republic of San Marino - 2014

Alu Bender Photo
Horizontal and vertical
pre-cut
These two saw blades are pre-
cutting the paper to avoid lifting
and damages to the edges.
15
Two blades ø 80 mm turning at 12.000 RPM with a special design of the teeth are precutting
the paper to avoid damages and “prepare” the excess to be milled off.
One side of the teeths have been sharpened at 70° making the profile very thin.
Excellent dust hoods collect all dust produced.
These blades are extremely important to avoid that the printed paper raises from its
substrates and allows a good finishing of the corners.
As it is installed on all our machinery for wood working this unit is fully proven and reliable.
The high frequency motors are built to last and the power is 0,37 Kw each.© SAMEC S.p.a. - Republic of San Marino - 2014

Alu Bender Photo
Milling off the remaining
excess
This cutterhead “eats” away the
exceeding material allowing the
following bending process.
16
One cutterhead with 12 knives ø 80 mm turning at 12.000 RPM and 0,5 Kw power can mill
away the excess sending all the dust to extremely efficient dust hoods.
All hoses of the precut and milling off are collected into a ø120 mm main dust hood collector.
This cutterhead is installed on a support that allows all fine adjustments for a perfect job.

Alu Bender Photo
Horizontal and vertical
pre-cut
Milling off the remaining
excess
17
This simulation of the first two processes explains and shows the “naked” tools for a better
understanding.
Our experience in tools has given us a total freedom of choosing the right ones for a good
work and a good productivity.

Alu Bender Photo
Creasing wheel
Creates a folding line that allows the
paper to fold perfectly.
18
Made of a thin metal disc with a radiused contact surface that creases the paper against a
rubber roller which is underneath.
Small, not technologically complicated, this little unit has a big importance since paper does
not bend in straight lines.

Alu Bender Photo
Glue Gun
Applies the hot glue in a straight line
to allow the holding of the bent edge
of the board.
19
Fully controlled by the PLC this glue gun has 5,0 Kg. capacity tank allowing a lot of meters of
continuous glueing. Its position can be easily set to allow a perfect application point.
Without this unit the all processes cannot take place. Built in Italy this glue gun is used in
several fields including carton boxes glueing.
The PLC controls the heating up, the stand by, the opening and closing of the glue
distribution.

Alu Bender Photo
Bending rollers
Allows to bend over one of the two
surfaces of the board against the
core.
20
Five metal and chromed rollers, at different tilt (18°, 36°, 54°, 72°, 90°), are bending along the
line made by the creasing wheel.
In this way one of the surfaces (typically the printed one) is bend over the core.
In this way the glue is compressed against the honeycomb determining the bonding.
This unit is totally mechanical and it is not controlled PLC.
From these BENDing rollers the machine takes its name…

Alu Bender Photo
Holding and cooling
device
Allows to keep the edge in place
while the hot glue gets colder.
21
A flat belt driven by the panel itself allows the cooling of the glue.
On the top and on the bottom of the belt there are two lines of compressed air blowing to
cool the glue inside the core.
Panels with wide cores require a high amount of glue. The glue is hot, so if it is not cooled
down it will not keep the edge in place.
The PLC controls the blowing of compressed air from the beginning to the end of the board
to avoid useless air consumption.

Alu Bender Photo
22
The four sides
This process can be done on all 4 sides
of a straight panel.
Here it can be clear how the panel looks
better…

Alu Bender Photo
23
Thank you very much for
reading and understanding our
technology…
Wait… I almost forgot…

Alu Bender Photo
24
There is one more thing…

Alu Bender Photo
25
This machine can also process DIBOND®
and any digital printing Aluminum
composite panels.
Click here to watch the video
http://goo.gl/0zhXXY
.

Alu Bender Photo
27
Casadei Industria is a Company 100% owned by the Muratori Family who
are all actively working.
We manufacture machines in the Republic of San Marino under the
company name Samec Spa. We have two facilites totalling 5000 sq/mt of
space and ca. 70 employees.
We are actively manufacturing machines for wood working, architecture
(façade cladding) and visual communication.
Thank you!

Alu Bender Photo Eng

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