Anyone looking to optimize their particle foam processing should use cost-effective systems. That is exactly what Hordijk has done – the Dutch company invested in a Kurtz POLY FOAMER with CoreLess technology, a system that is both high-performance and sustainable for efficient EPS processing.
The history of the Delft-based family business Royal Hordijk dates back more than 100 years. Initially, the company produced wooden materials, wooden crates, and building materials made of wood. Gradually, wood was replaced by aluminum and steel, and plastic began to be used for packaging. In 1969, Hordijk began processing EPS to manufacture packaging for cucumbers. Today, Hordijk is known far beyond the borders of the Netherlands as an EPS processor, producing packaging, insulation boards, building materials, technical parts, and planters.
Constantly seeking ways to make its products even more sustainable and efficient through appropriate manufacturing processes, Hordijk recently took another significant step forward with its EPS production: “We have invested in a new Kurtz POLY FOAMER equipped with CoreLess technology – one of the most energy-efficient and innovative molding machines currently available on the market,” reports Sander de Jager, Operations Manager at Hordijk EPS Verpakkingen en Isolatieproducten.
CoreLess – simply strong
This machine produces a foundation U-shell – an efficient construction product used to build a robust foundation for new residential homes and additions in the Netherlands. When processing particle foam, the focus is on the highest and most consistent quality, the fastest possible cycle time, and maximum energy savings. This is precisely where CoreLess technology comes into play, with consistent mass reduction, the smallest possible steam chamber volume, and thermal decoupling of the individual cavities.
From Product Development to Production System Development
For this U-shell project, the three project partners – Hordijk, Kurtz Ersa, and Doroteo Olmedo S.L. – joined forces. The goal was to create the largest CoreLess machine currently available, equipped with the world´s largest energy-efficient CoreLess mold – and insights gained directly from the construction site were incorporated into the development of the new product line of EPS foundation U-shells.
By investing in this new technology, Hordijk made a conscious decision to prioritize sustainable solutions. “Thanks to CoreLess technology, consumption of steam, compressed air, and energy can be significantly reduced, while at the same time production capacity increases and the carbon footprint is reduced,” says Hordijk Operations Manager Sander de Jager. In doing so, Hordijk reaffirms its strategic focus as a pioneer in sustainability and energy efficiency. This also includes providing robust, sustainable solutions for the construction and industrial sectors and working closely with customers and suppliers to continuously improve and further develop its products. Compared to similar systems, Hordijk has been able to reduce its energy consumption by more than half with CoreLess technology – cycle times have also dropped by over 50%!
Sebastian Schreck, Area Sales Manager at Kurtz Protective Solutions, reflecting on the successful project: “Our customers are looking for and need sustainable process solutions, especially in terms of energy savings and cycle times, but at the same time they also require the highest degree of flexibility. Machines equipped with CoreLess technology can be converted to a system with a standard steam chamber if necessary, should the application or the machine´s area of use change. These requirements were successfully coordinated and implemented in this project.”
