Heavy Layer - Laminated Sound and Heat Insulation Sheet
Heavy Layer – Compound Sheet Process Solutions
Monomex develops customized extrusion and compounding lines for the production of highly filled Heavy Layer sheets, also known as laminated sound and heat insulation sheets, for automotive and industrial insulation applications.
Heavy Layer sheets are widely used in the automotive industry to reduce engine noise, road noise, vibration and driving-related sound transmission. These sheets can be laminated with felt, foam, nonwoven materials or carpet layers to achieve improved acoustic insulation, thermal insulation and vibration damping performance.
The extruded highly filled compound sheets can then be processed by pressing, thermoforming, deep drawing or cutting to produce vehicle floor insulation, trunk liners, engine compartment insulation, under-carpet layers and technical sound barrier components.
Process Quality in Heavy Layer Production
Heavy Layer production differs significantly from standard sheet extrusion. It requires high filler loading, low polymer content, high density, controlled melt viscosity and stable sheet thickness. For this reason, raw material feeding, filler distribution, melt temperature, screw design, vacuum performance, filtration, calendering and lamination steps must be optimized as one integrated process.
Monomex Heavy Layer production lines are specially designed to achieve stable processing and high product quality in highly filled EVA, POE, PE, EPDM or special elastomer-based formulations.
Heavy Layer Production by Split-Feed Method
One of the most reliable production methods for Heavy Layer compounds is the split-feed process. In this method, backbone polymers, elastomers, small additives and selected liquid components are fed into the main inlet of the extruder in controlled streams. Abrasive and high-volume mineral fillers are added downstream through a side feeder.
With this process concept, mineral fillers are incorporated into the compound after the polymer melt has been prepared. This reduces abrasive wear on screw and barrel components while improving mixing stability and final sheet quality.
The split-feed method is especially advantageous for formulations containing:
Baryte
Calcium carbonate
Talc
Dolomite
Mineral filler blends
Recycled filler-based contents
High-density filler systems
High-Filled Compounding with MEX Twin Screw Extruder
Monomex MEX twin screw extruders provide high mixing efficiency and precise process control for homogeneous distribution of high filler contents in Heavy Layer production. Screw configuration, feeding points, filler inlet zones, vacuum sections, temperature profile and torque capacity are customized according to the target formulation.
With MEX twin screw extruder technology, manufacturers can achieve:
High-filled compound production
Homogeneous mineral filler distribution
Controlled melt temperature
Stable pressure and flow
Reduced thermal stress
Recipe-specific screw and barrel configuration
High process flexibility
Reliable continuous production
Filler Addition with Side Feeding
Mineral fillers such as baryte and calcium carbonate used in Heavy Layer formulations are high-density and abrasive materials. Feeding the entire filler content through the main inlet can negatively affect process stability and increase wear.
Monomex uses twin screw side feeder systems to introduce mineral fillers into the melt phase in a controlled manner. This enables higher filler loading, reduced feeding fluctuations and a more homogeneous final sheet structure.
Direct Extrusion and Inline Compounding
In addition to the split-feed method, Heavy Layer sheets can also be produced by direct extrusion or inline compounding. In this process concept, compounding and sheet extrusion are integrated into one continuous production line.
Inline compounding is especially advantageous for manufacturers seeking high throughput, reduced intermediate handling and a shorter production flow. Based on the formulation, sheet thickness, filler ratio and lamination requirements, the Monomex engineering team defines the most suitable process configuration.
Laminated Sound and Heat Insulation Sheet
Heavy Layer sheets can be combined with different surface materials according to application requirements. Lamination improves acoustic damping, thermal insulation, mechanical strength and surface performance.
Typical lamination materials include:
Felt
Foam
Nonwoven surfaces
Carpet layers
Technical textile surfaces
Barrier films
Special insulation layers
Monomex production lines can be fully integrated with calendering, sheet die, cooling, haul-off, lamination and cutting systems.
Typical Application Areas
Monomex Heavy Layer and laminated compound sheet lines are designed to produce high-performance sheets for automotive and industrial insulation applications.
Typical applications include:
Automotive floor insulation sheets
Engine and transmission compartment sound barriers
Trunk insulation sheets
Under-carpet heavy layer applications
Vibration damping sheets
Sound and heat insulation panels
Industrial acoustic barriers
Technical composite sheet applications
Turnkey Heavy Layer Production Lines
Monomex designs complete process lines for Heavy Layer production, not only individual extrusion machines. Each line is configured according to target capacity, sheet thickness, filler loading, polymer type, lamination requirements, automation level and plant layout.
A Monomex Heavy Layer production line may include:
Raw material storage and conveying system
Gravimetric dosing units
Liquid additive dosing system
Main feeding system
Twin screw side feeder
MEX twin screw extruder
Vacuum degassing system
Melt filtration
Melt pump
Sheet die
Calender system
Lamination unit
Cooling and haul-off system
Cutting and stacking system
Automation and recipe management
Monomex Engineering Approach
Success in Heavy Layer production cannot be achieved only by using a high-torque extruder. It requires correct process design, controlled raw material feeding, wear-resistant screw and barrel construction, stable flow at high filler loading, precise thickness control and reliable lamination quality.
Monomex approaches each Heavy Layer project as a formulation- and process-driven engineering solution. Target product properties, material behavior, production capacity, energy consumption, maintenance requirements and final application are analyzed together to develop a customized production line.
Higher Performance in Heavy Layer Production with Monomex
In highly filled laminated compound sheet production, the right process design is critical for product quality, production efficiency and final application performance.
Monomex provides engineering-driven turnkey solutions for Heavy Layer, sound insulation sheet, heat insulation sheet and high-filled compound sheet production lines for automotive and industrial insulation applications.
Contact the Monomex engineering team to build a new Heavy Layer production line, modernize your existing system or improve your process quality.