CORDIS provides links to public deliverables and publications of HORIZON projects.
Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Exploitable results
Production equipment:
An optimised new PU injection prototype has been developed, manufactured and tested as a high-grade modular and flexible system. The characteristic features of the new development include:
-Integrated construction with a SPC.
-Quick change of the mixing screw.
-Choice of different mixing screw-revolutions per material.
-Self-cleaning mixing head without using solvents.
-Choice of different injection throughputs.
-Multi-components processing (up to 4 components).
-Multi-colour processing (up to 4 colours).
-Quick colour change without material loss.
A new modular transport system for moulds and lasts has been developed, manufactured and tested which increases the productivity strongly. Changes of moulds and lasts will be carried out automatically with quick connection of the external electric, pneumatic and hydraulic sources.
New tool systems have been developed, manufactured and tested. A new optimised version of a flexible closing line for moulds based on a resin has been developed and tested, which allows production of variable upper thickness easier and quicker. A new synthetic prototype mould production has been developed which allows low cost moulds - compared with traditional moulds reduced by factor 6 - and quicker delivery by the factor 20, which results in a short product development process.
PU material:
Regarding the reduction of raw material new prepolymers have been developed to fulfil the requirements for the production of dual density soles in the direct soling process. These systems have been tested in production tests and optimised. New mould geometries have been developed and tested which resulted in 25% raw material saving and reduced process time.
Regarding recycling mechanical recycling of solid scrap from polyurethane shoe sole production has been investigated. It resulted, as tests have showed, that it has been possible to use up to 20% by weight of the granulated scrap depending on the particle size but with reduced quality.
The application of external release agents by spraying has been reduced down to approximately 10% of the original value without loosing any quality with a new developed test system.
Beside this a new colour paste that contains release agent (Internal Mould Release) has been developed and tested. This allows reducing the amount of external release agent by 100% and reduces process time.
Planning and control:
The algorithms for planning the PU moulding production has been developed based on a new linear programming software package which main benefit is, that it protects the end user from having to understand about the formulation of the problem or the running of the solver. The innovative scheduling software allows to work interactively to experiment with alternative work mixes.
A prototype of a control system to monitor relevant parameters of the production process has been developed. This included the development of a new sensor for the determination of the material quality based on microwave technology. The control system developed and tested is a modular system that can be used as control system for any process with less than 100 variables to monitor.
Human resources:
Training schemes and training material for Proactive Training Courses have been developed. A specific course with the purpose of creating a model for basic training of members of future autonomous groups has been developed, which favourably combines theory and practical work. Production groups containing 5 to 7 employees have been established and assessed as an important precondition to enable the groups to function homogenously and with an integrated delegation of tasks.
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