Polyurethane
Solutions
Advanced PU foaming technologies — from VIP encapsulation and mold carriers to automated production lines and added-value services.
VIP
Encapsulation
Problem
Traditional VIP insulation uses slabstock foam cut and glued manually — creating thermal bridges, air gaps, and requiring labor-intensive post-processing.
Solution
Monolithic Reaction Injection Molding (RIM) encapsulation. No cutting, no gluing. Functional geometries (tongue-and-groove, interlocks) molded directly. Zero secondary machining.
- Puncture & scratch resistant protective shell
- Integrated joining features in one step
- Multiple PU material options (rigid, integral, flexible)
- Applications: cold-chain, refrigeration, building
EDU
Encapsulation
Problem
Multi-component housings and insulation layers introduce interfaces, NVH paths, and assembly complexity in compact e-drive systems.
Solution
Monolithic PU encapsulation integrates damping, sealing and insulation in a single RIM process — eliminating interfaces and secondary operations.
- NVH reduction (structure + airborne)
- Electrical insulation & environmental sealing
- Integrated mounting features
- Reduced part count and assembly effort
Heat Pump
Encapsulation
Problem
Layered insulation systems create thermal bridges, air gaps, and inconsistent acoustic performance.
Solution
Zone-tuned PU encapsulation combines open-cell acoustics and closed-cell insulation in one seamless structure.
- No thermal bridges, stable insulation performance
- Integrated acoustic damping
- Moisture-resistant sealed system
- Simplified assembly
ICE Component
Encapsulation
Problem
Separate shields, covers and dampers increase complexity under high thermal and chemical exposure conditions.
Solution
Robust PU encapsulation provides integrated thermal shielding, damping and environmental protection in one molded part.
- Thermal and chemical resistance
- Vibration and noise reduction
- Impact and abrasion protection
- Integrated fixation features
Compressor
Encapsulation
Problem
Discrete acoustic, thermal and structural elements create interfaces, inefficiencies, and assembly effort.
Solution
Multi-density PU encapsulation delivers functional zoning (acoustic, insulation, structural) in a single molding step.
- High acoustic absorption
- Vibration isolation
- Thermal insulation
- Reduced components and assembly time
Mold
Carriers
Problem
Heavy molds cause misalignments, slow changeovers, and require manual handling — limiting throughput and consistency.
Solution
Precision-engineered mold carriers — horizontal, vertical, rotary, shuttle, custom modular. Zero misalignment, fast changeovers, Industry 4.0 sensor monitoring.
- Horizontal / Vertical / Rotary / Shuttle configurations
- Fail-safe clamping & precision closure
- Heating / cooling / vacuum / hydraulics ready
- Predictive maintenance connectivity
Production
Lines
Problem
Choosing the right production line for your volume — one size doesn't fit all. Wrong choice means wasted investment or bottlenecked output.
Solution
Full range from low-volume prototype lines to high-output automation. Manual stationary, automated gantry, rotary carousel, racetrack lines — matched to your exact volume and footprint.
- Manual stationary for prototyping & low volume
- Automated gantry for medium-high volumes
- Rotary carousel for 24/7 operation
- Racetrack for highest output per m²
Automated Double Sided Adhesive
Tape Application
Problem
Manual taping and assembly is slow, inconsistent, and requires many operators — driving up cost and quality variance.
Solution
Automated taping systems — 6 sec/part, 100% camera inspection, single operator. Applicable beyond EPP parts to any production requiring precision placement.
- Up to 6 seconds per part cycle time
- 100% camera-based quality inspection
- Automatic finger-lift tab placement
- Custom-made adjustments for any production need
Multi-Tools for
PU Development
Problem
Developing new PU foam references requires separate expensive molds for each variant — multiplying investment and slowing iteration.
Solution
One carrier mold with interchangeable inserts — test multiple references without new molds. Faster prototyping, lower investment, less risk.
- Single mold for multiple PU foam references
- Fast insert changeover without mold swap
- Accelerated prototyping and industrialization
- Proven in real-world automotive environments
Trial Molding
Center
Problem
No in-house testing capability — customers can't validate molds before committing to serial production, increasing risk.
Solution
Dedicated technical center with 3 PU machines, robotic precision pouring, laboratory for material characterization (mechanical and thermal properties), university collaboration (FTPO).
- Mold testing and process validation on-site
- Prototype to serial mold validation
- Improvement identification before serial
- Hardness testing and material characterization
- Component industrialization
- FOT — First-Off-Tool parts
Uptime & Operational
Excellence Services
Problem
Equipment downtime, lack of production visibility, and no remote support — leading to unplanned stops and lost output.
Solution
Alba Service Care (preventive maintenance), Alba Remote SmartLine (VPN remote monitoring), Alba Analytics (Power BI dashboards — OEE, scrap, energy).
- Annual service packages with full documentation
- Live system monitoring via PC / tablet / mobile
- Power BI dashboards for OEE and production KPIs
- Integration with PLC, MES and ERP systems
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