Thinking about launching a sandwich panel manufacturing business?

Now is the ideal time. According to Fortune Business Insights in 2023, the global sandwich panel market was at 9.91 billion dollars and is expected to grow from 10.70 billion dollars in 2024 to 20.51 billion dollars by 2032,with a compound annual growth rate (CAGR) of 8.4%. Demand is rising fast, especially in cold storage, industrial facilities, and commercial buildings, making a sandwich panel production line a strategic and scalable investment.

Long-term success in this industry doesn’t come from chasing the cheapest machines; it comes from choosing the right production technology, truly understanding the manufacturing process, and partnering with a supplier who supports you every step of the way.

At Fineagles Advance Engineering, we help new producers build efficient, future-ready factories with fully integrated production lines, from decoiling the metal sheet through to the final product packaging. Whether you’re producing PU/PIR panels for cold rooms or mineral wool panels for fire-safe structures, this guide walks you through every step, powered by Fineagles’ advanced engineering.

Continuous vs. Discontinuous Production

Choosing the right production method is one of the first critical decisions in setting up your factory. The two main approaches, continuous and discontinuous, serve different needs and business models.

Continuous Production: For High Output and Consistency

The continuous Sandwich Panel production lines are the industry benchmark for a modern and high-capacity panel manufacturing. They deliver export-ready panels with consistent quality. Operating like an automated assembly line: metal coils enter one end, pass through shaping, foaming, pressing, cutting and panel handling zones, and exit as fully formed panels, non-stop. They require more upfront investment, but pay back quickly with higher margins and lower waste.

A continuous line typically includes decoilers, roll-forming, double-belt laminator/press, PU metering System+ mixing, a Cutting band saw, cooling conveyors, stacking system and packing unit”

These lines are designed for PU & PIR Sandwich Panel Production , and mineral wool panels, where even foam distribution and strong adhesion are critical. Running at speeds of 5 to 15 meters per minute (depending on foam chemistry, panel thickness, and profile type), continuous systems make it possible to achieve high-volume production with consistent quality and reduced waste, perfect for exporters and large-scale manufacturers.

Discontinuous Production: A Flexible Entry Point

Discontinuous Panel Production lines are well-suited for low capacity or cold room door producers, custom orders or regions with developing markets. Panels are produced individually, using pre-cut materials bonded in a hydraulic press. They’re more affordable at the start, but less efficient and harder to scale. Many small producers eventually outgrow discontinuous lines as demand increases.

How It Works: From Coil to Completed Panel

Let’s follow the process of a continuous PU/PIR sandwich panel production line, the most widely used system for high-performance insulation panels.

Fineagles – PU & PIR Sandwich Panel Production Lines

Decoiling & Pre-Treatment
Production begins with two coils of pre-painted galvanised sheet (PPGI) fed into the line. The sheets pass through a unit that removes oils, dust and surface contaminants.

Roll Forming

Next, the metal sheets enter the roll forming machine, which shapes them into ribbed, trapezoidal, or flat profiles. This step not only defines the panel’s look but also reinforces its rigidity and overall structural strength.

Fineagles machines feature profile libraries and quick-change cassettes, allowing fast switchovers between profiles and minimizing downtime, an essential advantage for manufacturers serving multiple markets.

pre-heating unit

a pre-heating unit ensures the steel temperature is optimal for chemical bonding. This stage creates the perfect surface for bonding with the foam core.
Foaming & Lamination
At the heart of the process is the foaming station, where a high-precision metering unit doses polyol and all other components, mixes them in a high-pressure static mixer, and then combines them with isocyanate in the mix head before injection between the moving steel sheets. As the chemicals react, they expand into a dense, insulating foam that fills the entire cavity.

After foaming, the panels pass into a double-belt laminator with multi-zone heating and pressure control. This ensures continuous bonding of the steel facings to the expanding foam, guaranteeing perfect adhesion, flatness, and dimensional accuracy.

Curing The curing process takes place throughout the double belt conveyor, typically up to its standard length of 30 m / 40 m .”
Cutting
Band saw unit automatically cuts each panel to the desired length.

Cooling:

The cooling conveyor section allows sandwich panels to rest while the PU material gradually cools to a stable temperature. This controlled process prevents sudden temperature changes that could cause deformation or defects in the panels.

Stacking:

The stacking system collects and arranges finished sandwich panels in an organized way for easy handling and packaging. This ensures efficient workflow, protects panel surfaces, and prepares them for smooth transfer to the packaging stage.

Packing:

The packing unit secures finished sandwich panels with protective wrapping and strapping for safe storage and transport. This step safeguards product quality, reduces handling damage, and ensures panels reach customers in perfect condition.

This entire process runs continuously, producing hundreds of meters of high-performance panels daily, with minimal manual labor.

For mineral wool, the process varies slightly. Mineral wool cores are pre-cut and inserted, requiring vacuum-assisted lamination for full contact.

Choosing the Right Core: Match Material to Market

The core material defines your panel’s performance, from insulation to fire safety.

Core Type	Best For	Thermal Conductivity	Fire Rating
PU / PIR Foam	Cold rooms, energy-efficient buildings	As low as 0.022 W/mK	B1/B2 (PIR can rarely reach A2)
Mineral Wool	High-rise, industrial, fire-critical zones	0.034–0.038 W/mK	A1/A2 (non-combustible)

A sandwich panel production line requires more than machinery; the factory infrastructure is critical for performance, safety, and compliance. When planning your facility, consider:

• Factory Layout: Plan for at least 90 meters of linear space.
• Power Supply: A stable, high-capacity electricity source to ensure uninterrupted production and avoid costly downtime.

Power Requirements • Start-up Phase: ~500–600 kW • Continuous Operation: ~250 kW • Estimated Daily Consumption (for one 8-hour shift): ~2,350 kWh/day

• Ventilation & Air Filtration: Proper air circulation and extraction systems are essential to manage fumes and maintain a safe, healthy work environment.
• Chemical Handling (Foam chemical components): PU and PIR production involves reactive chemicals. Dedicated storage, controlled temperature systems, and safe transfer lines are crucial for consistent foam quality and operator safety.
• ATEX & Fire Safety Standards (Specially in the foam injection area): Compliance with international safety regulations (e.g., EN 13501-1, ATEX certification in explosive atmospheres) protects both your workforce and your facility.

Fineagles’ high-pressure PU metering systems are designed and manufactured in line with the world’s latest safety standards. This guarantees advanced performance, safety, and reliability for modern sandwich panel production lines.

• Operator Training: Skilled staff are the backbone of efficient production. Proper training on machine operation, safety protocols, and process control ensures stable output and minimizes errors.

At Fineagles, we don’t just deliver machines. We help you design a safe, compliant, and efficient production environment. From utility planning to operator training and 24/7 technical support, we make sure your line runs smoothly and sustainably for a successful business.

Why Support Matters More Than Price

One of the biggest blind spots for new producers is underestimating after-sales support. A production line is more than just machinery; it’s a system that needs troubleshooting and care. When a foaming unit stops working in the middle of the night, you don’t want to wait days for help.

That’s why at Fineagles, we make sure our clients get:

• 24/7 remote technical support;
• Rapid on-site support provided in case of emergency requirements
• Commissioning and operator training included
• Free feasibility studies and layout planning before installation

We don’t just deliver a line; we build long-term performance and reliability into your business.

Avoiding the Common Traps

The biggest mistakes in starting a sandwich panel factory often come from focusing only on purchase price while overlooking the real performance factors. Here are the pitfalls to avoid:

• Build Quality of the Machinery: Poor welding, low-grade components, or weak frames lead to vibration and reduced precision.
• Level of Automation: Manual adjustments slow production and increase human error. Choose systems with advanced PLC control, recipe storage, and monitoring.
• Energy Consumption: Inefficient lines increase operating costs and reduce margins over time.

Fineagles’ Advantage: Our production lines are engineered to eliminate these traps with certified performance, advanced process control, and robust design. That’s why global producers trust Fineagles for projects where panel quality means business credibility.

Fineagles Approach

To make sure our clients succeed, we provide:

• Virtual and on-site factory tours
• Custom line design tailored to your needs
• Process consultation to optimize production from day one

Start Smart, Grow Strong

If you’re planning a sandwich panel production line, understanding the full scope, from material selection to machine integration, is the foundation of a successful operation.

With growing demand for energy-efficient, modular, and fire-safe building solutions, now is a strategic time to invest in reliable manufacturing technology.

Whether you’re evaluating continuous vs. discontinuous methods or deciding between PU/PIR or mineral wool capabilities, we’re here to help you make informed decisions.

For technical documentation, process consultation, or a preliminary layout review, contact us today . We provide no-obligation support to help you plan with confidence.