Flexiwall partition solves thermal challenge for high-temperature manufacturing

Flexiwall partition manages heat radiation and protects staff

A leading manufacturer of wood-based products – particleboard, thermally fused laminate, flooring, and edge banding – have multiple plants worldwide. When the manufacturing company’s US team needed to manage the heat generated during part of its production process, they turned to Westgate Global, who had been recommended after a successfully completed project at the company’s European HQ.

Sustainability has been central to the company’s operating model from the outset. Post-consumer wood waste is collected, processed, and reintegrated into new products. At the manufacturing plant in North Carolina, the production process culminates in one of its most demanding stages: freshly pressed boards emerge from the ContiRoll press at approximately 270°F and are cut into large panels before being moved to one of three star coolers; large rotating structures that continuously turn the panels, allowing them to cool and stabilize before they reach the sanding lines.

Intense heat radiation in a live production environment

The star cooler area generates significant heat radiation. For the comfort and safety of staff working on either side of the production space, the extreme temperatures needed to be managed. With the cooling process taking place amid other processes, including shredding, milling, separating, forming, pressing and sanding, the enclosure needed to accommodate the realities of an active industrial environment and the various ancillary processes, without disrupting ongoing production.

The partition needed to fit around existing infrastructure and penetrations from pipes and machinery. This meant a traditional wall was not an option.

Flexiwall: engineered for complex industrial environments

Westgate Global recommended and installed Flexiwall. The tensioned industrial fabric partition wall is ideal for large spaces, where it can be used to segment spaces, manage temperature and humidity, reduce noise and prevent cross-contamination. The heavy-duty fabric barriers are rated to withstand operating temperatures up to +932°F and are independently certified to a comprehensive range of fire safety standards. At the North Carolina plant, the Flexiwall partition was designed to contain heat radiation from the star cooler area, providing a reliable thermal barrier that protected staff comfort on the other side of the partition.

Where a rigid wall would have required costly modifications or left awkward voids around existing equipment, Flexiwall’s flexibility meant it was an ideal solution. The partition was designed to fit around existing ducts and pipework, with strip door openings and roll-up panels, allowing conveyors to pass through cleanly without leaving gaps that would compromise the seal.

Partitioning that moves with the operation

The installation ensured that staff on the other side of the partition were protected from heat radiation, production continuity was maintained throughout the installation process, and the enclosure was able to adapt to the demands of the fast-moving production environment. Should equipment in the star cooler area need to be reconfigured in the future, Flexiwall can be removed and reinstalled without damaging the building or the system.

A sustainable partition solution

With the company’s strategy driven by the guiding principle “Shaping a sustainable future”, its commitment to responsible manufacturing extends to choosing the right products, solutions and partners. Flexiwall is designed to be fully reusable, adaptable, reconfigurable, and relocatable, minimising waste as project requirements change. Westgate Global’s commitment to sustainability is independently verified through its EcoVadis Silver rating, a recognised benchmark of responsible business practice. In choosing Flexiwall, the manufacturer selected not just a system that solved a complex engineering challenge, but a supplier whose values align with their own responsible approach to manufacturing.

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