A single universal mold for PUR encapsulation water tanks

Flexible-to-use and semi-automated molds reduce cost

Mindelheim, 20.03.2024. We have a new product to offer to manufacturers and suppliers of solar systems, heat pumps, oil and gas heating systems, solid fuel boilers and components for hot water supply in low-energy houses: our mold making department develops and manufactures flexible-to-use molds for the encapsulation of water tanks of various sizes with insulating polyurethane rigid foam (PUR).


Universal encapsulation molds are easy to adapt in just a few steps

Thanks to their design, our standard molds only require a few steps to be adapted to varying tank sizes, model versions and types of connections. They can be operated manually or, on the basis of a PLC control system, semi-automatically and then either hydraulically or pneumatically.

Polyurethane offers excellent insulating properties

The layer of fine-cell polyurethane rigid foam with a closed cell structure that is created when the tanks are encapsulated ensures that gas transport is delayed. This results in particularly good insulating properties so that the stored hot water maintains its temperature for a long time.


PUR universal molds increase economic efficiency

Encapsulation with a few universal molds increases the economic efficiency of water tank production. Mold cost can be reduced significantly in particular when small batch sizes are produced with a large variety of types. Furthermore, the easy handling of the mold and a sensor system for process monitoring and control ensure short set-up times.

Good experience with universal encapsulation molds

BBG has already gathered good experience with the series-production molds used for encapsulating drinking and process water tanks as they are already in use at a number of satisfied customers.

Insulation for tanks with a capacity ranging from 100 to 1,000 liters

The most versatile molds can be used to encapsulate up to 15 different tank models with capacities ranging from 100 to 1,000 liters. They are used in combination with solar systems, heat pumps, oil or gas heating systems and solid fuel boilers, as well as for hot water supply in low-energy buildings.


Manufacturers can save the money otherwise spent on many expensive molds

Most manufacturers of water tanks offer their customers a large number of different model versions. These differ in terms of size, equipment and location of connections for water inlet and outlet pipes, threaded sleeves, temperature sensors and other elements. “Many producers have more then hundred molds in stock. This means that many thousands of euros are tied up in molds that can often only be used for a single tank model“, Gerhard Hörtrich, sales and project manager at BBG, describes the situation in the industry.

BBG cooperates closely with their customers

BBG develops their universal molds in close cooperation with their customers. In the process, they clarify, among other things, which sizes and insulation thicknesses, how many tank versions and which equipment options are desired.

Exact specifications and a high degree of precision

BBG then uses those specifications for exactly designing the desired mold. To ensure that the mold can be used universally for all versions, the upper edge of the foam can be adjusted to match the tank height by means of a movable lid. There are also exchange strips for type-specific elements, which are inserted into the mold to match the model. We attach great importance to a high level of precision of all parts to ensure that no polyurethane leaks to the outside despite the high internal pressure during the encapsulation of the tank.

Semi-automated encapsulation of water tanks

For encapsulation purposes, the water tank is placed on the retractable base plate of the mold and rolled into the open upright mold shells. Type-specific coded strips are mounted in the mold to accommodate the model-specific equipment features.

In a semi-automated production process, the PLC control checks whether or not the mold is prepared correctly. Sensors automatically detect the tank model and the position of internal parts. A status inquiry with position control checks whether the clamping device closes the mold correctly. Encapsulation can only be started once the control system sends the enabling signal. While the polyurethane is injected into the mold and cures, externally mounted heating mats ensure a constant temperature and an optimum encapsulation process.

BBG is one of the best toolmakers in the German-speaking region

We at BBG rely on more than twenty years of experience in toolmaking. In 2023, we were once again honored as one of the best toolmakers in the German-speaking region within the framework of the "Excellence in Production" competition. This is the fourth time we have reached the final of this prestigious competition, which is organized by the Machine Tool Laboratory WZL of the RWTH Aachen University and the Fraunhofer Institute for Production Technology, both based in Aachen.

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