Sandwich PUF Panel Manufacturer in Pune
Sandwich PUF panels in Pune
A sandwich PUF panel is an insulated building panel. It has two metal skins bonded to a rigid polyurethane (PUF) or PIR foam core. Panels like these form the walls, ceilings and roofs of cold rooms, freezer rooms, clean rooms and factory buildings. Falcon Refrigeration designs, makes and installs sandwich panels in Pune and across Maharashtra.
This page explains how the panel is built, how the joints work and where each type is used. To choose the right thickness for a set room temperature, see our guide to PUF panel thickness by temperature.
How the panel is built
Every panel has three layers that work together. The two skins carry the load and protect the foam. The core gives insulation and keeps the skins apart, so the panel stays stiff over long spans.
Outer skins: PPGI, stainless steel or aluminium
PPGI (pre-painted galvanised iron) is the common choice for walls, ceilings and roofs. The zinc layer stops rust, and the paint coat adds colour and a wipe-clean surface. Skins are usually 0.4–0.8 mm thick.
Stainless steel (SS 304) skins suit food processing, dairy, meat and pharma rooms. They stand up to frequent wash-down and cleaning chemicals. Many buyers use SS on the inside face only and PPGI outside to control cost.
Aluminium skins are lighter and do not rust. They are used where weight matters or where the room is near the coast.
The core: PUF or PIR
The core is a rigid, closed-cell foam made by mixing polyol and isocyanate. PUF foam for panels is usually about 40 ± 2 kg/m³ in density. Its thermal conductivity is roughly 0.022–0.025 W/m·K, so a thin layer insulates well.
PIR (polyisocyanurate) is a related foam with better fire behaviour. It chars on the surface and spreads flame more slowly than standard PUF. PIR is often chosen for large warehouses, roofs and rooms with strict fire rules.
No foam core is fully non-combustible. Always ask for the fire-test report for the exact grade you are buying.
How the core bonds to the skins
Liquid foam is poured or injected between the skins, then it rises and cures. As it cures, it sticks firmly to both skins. Panels are made on a continuous line or in a heated press, then cut to the length you order.
A good bond means no hollow spots and no peeling skin. Tap tests and cut samples show voids that would let heat and moisture in.
Panel joints and sealing
Most heat and moisture problems in an insulated room start at the joints, not in the panel face. That is why joint design matters as much as foam thickness.
Tongue-and-groove joints
Each panel edge has a tongue on one side and a groove on the other. Panels slot together to form a tight, continuous wall. This joint is common for walls, partitions and roofs.
Cam-lock joints
Cam-lock panels have hooks foamed into the edges. A key turns the lock and pulls the panels tightly together. Cold rooms and freezer rooms often use cam-lock joints because they seal well and can be taken apart later.
Sealing, trims and corners
Joints are sealed with silicone or PU sealant and covered with metal trims or flashings. In freezer rooms, the warm side of each joint must be fully sealed. Otherwise moist air enters, turns to ice and slowly damages the foam.
Clean rooms use flush joints and coved corners with no ledges where dust can settle.
Where sandwich panels are used
Cold rooms and freezer rooms
Walls and ceilings of chilled and frozen stores are built from panels with cam-lock joints. Thicker panels are used as the room gets colder. Freezer rooms also need an insulated floor and a pressure relief port in the wall.
We supply the panels with the refrigeration and doors as one job. See our cold room manufacturer in Pune page for complete rooms. For other districts, see our cold rooms across Maharashtra page.
Clean rooms
Pharma, electronics and food-packing units use panels for clean room walls and ceilings. Smooth skins, flush joints and coved corners make the room easy to wipe and sanitise. Matching flush doors keep the seal tight; see our cold room and clean room doors.
Roofing
Roof panels have a ribbed (trapezoidal) top skin that carries rain off and adds strength. The foam cuts heat gain from the sun, so the space below stays cooler. They are used on factories, warehouses and sheds.
Walling and partitions
Wall panels go up quickly on a steel frame and need no plaster or paint. They are used for factory walls, partition walls and insulated sheds. For complete prefab site offices and cabins, see our PUF panel shelters.
Typical specifications (confirm for your project)
The values below are common industry ranges. Your actual panel is specified for your room, load and site.
| Item | Typical range |
|---|---|
| Skin material | PPGI; SS 304; aluminium |
| Skin thickness | 0.4–0.8 mm |
| Core | Rigid PUF or PIR, CFC-free |
| Core density | About 40 ± 2 kg/m³ |
| Thermal conductivity of core | About 0.022–0.025 W/m·K |
| Panel thickness | 50–150 mm, chosen by room temperature |
| Cover width | About 1,000–1,200 mm |
| Length | Cut to suit room height or roof span |
| Joints | Tongue-and-groove or cam-lock |
| Surface | Plain, micro-ribbed or trapezoidal (roof) |
What to send us for a quote
- Use of the space: cold room, freezer, clean room, roof or wall
- Room temperature you need, if it is a cold room
- Length, width and height, or roof area and span
- Skin finish on each face: PPGI, SS or aluminium
- Any fire rule your insurer or client requires
- Site location and access for delivery
Send these details through our contact page and we will reply with a panel specification and price.
Frequently asked questions
What is the difference between a sandwich PUF panel and a plain PUF slab?
A sandwich panel has metal skins bonded to both faces of the foam. This makes it strong enough to form a wall or roof by itself. A plain PUF slab is bare foam used as insulation inside another structure. Slabs need separate cladding, while sandwich panels arrive ready to install with finished, cleanable surfaces.
Should I choose PPGI or stainless steel skins?
Choose PPGI for most cold rooms, roofs and walls, because it resists rust and costs less. Choose SS 304 where the room is washed often or handles meat, dairy or pharma products. A common middle path is SS on the inside face, where hygiene matters, and PPGI on the outside face.
Is PIR better than PUF for the core?
PIR is better when fire performance is the main concern, such as in large warehouses or roofs. It chars and spreads flame more slowly than standard PUF. Both insulate to a similar level. PUF usually costs less and suits most cold rooms. Check the fire-test report for whichever grade you choose.
Why do cold rooms use cam-lock joints?
Cam-lock joints pull panels tightly together with locks foamed into the edges. This gives an even, airtight seal, which stops moist air leaking in and forming ice. The locks also let the room be taken apart and moved later. Tongue-and-groove joints are common for roofs, walls and partitions.