Aluminium Composite Panel: The Manufacturing Process Explained

Aluminium composite panels (ACPs) can be produced using different methods. The two primary techniques for combining plastic core materials with two-sided aluminium sheets are the cold composite method and the heat composite method. This article will walk you through how a leading manufacturer produces ACP sheets while maintaining strict quality standards. 

Steps in Manufacturing Aluminium Composite Panels

Cleaning the Aluminium Coil

Cleaning the aluminium coil is the first step in producing composite aluminium sheets. Manufacturers typically source aluminium coils from reputable suppliers. During production and transit, the surface of these coils becomes covered with lubricants, anti-oxidants, and dirt, which can affect adhesion and therefore must be removed. The coils are degreased, de-oxidized, and chromatized by passing them through a series of tanks.

Degreasing and Chemical Treatment

Degreasing is a process used to remove oil and other impurities from the surface. Deoxidizing eliminates water from the coil, while chromatization creates an abrasive surface. This abrasive surface is essential for achieving good primer adhesion on aluminium surfaces.

Applying a Protective Layer

After cleaning and chemical treatment, a dense chemical protective layer forms on the surface of the aluminium coil. This chemical film enhances the coil's oxidation resistance and extends the life of the paint film. The core material is then melted into sheet form. An adhesive film—often sourced from established suppliers—is applied to both sides of the core.

PVDF/FEVE Coating

The cleaned aluminium coil is fed into a coater, where the outer surface is coated with a high-performance fluorocarbon resin. Two coats of paint and primer are applied to the panels. Manufacturers often use paints from well-known brands and can customize shades in-house. The topcoat is a fluorocarbon resin coating known as polyvinylidene fluoride (PVDF), which offers excellent weather resistance. Its strong UV resistance and anti-contamination properties keep the coated surface looking attractive. Fluorocarbon coatings are typically applied using a roll coating process and then dried at high temperatures. There are usually three layers of paint, and each coat must be baked at approximately 240°C for around 45 seconds.

Adding Top and Bottom Layers

To create a sandwich panel, coils are placed on the top and bottom of the core. The aluminium coil is laminated to the core using induction roller heating. The ACP is then brought to normal temperature using a cooling tower. At this stage, a protective film can be applied to the sheet. This self-adhesive film can be removed after installation and helps prevent damage to the surface coating during processing, transportation, and installation. The protective film often includes installation direction indicators for ACP cladding.

Customizing to the Right Size

Finally, the ACP boards and sheets are cut to customized lengths. Pallet packaging is commonly used to protect sheets during shipping. The sheets are loaded onto trucks with care to ensure they reach retailers, architects, and façade consultants in good condition. Consistent communication is maintained throughout the transportation process.

And there you have it—once manufacturing is complete, the ACP sheets are ready to enhance your façade.

Since the process involves technical details, it's advisable to consult in-house ACP experts for further clarification.