Helping Kögel strengthen links in the cold chain

Kögel is one of Europe’s top trailer manufacturers and an expert in temperature-controlled logistics. They understand the importance of finding new ways to make ground transportation more sustainable while meeting customer demands for maximum cost-effectiveness and a lower ecological footprint. Kögel’s new state-of-the-art production plant was supplied by Cannon and Manni to manufacture panels for their latest refrigerated model, the KÖGEL COOL LITESHELL.

The partnership between Kögel and Cannon began in 2019 when we proposed using our proprietary Foam & Film technology and applying structural reaction injection molding (SRIM) to discontinuous structural sandwich insulation panel production.

The first tests were conducted in our R&D lab by using a significantly smaller scale compared to the size of Kögel’s final 13×3 meter product. These early trials proved the concept’s viability and paved the way for us to design a fully customized, turnkey plant.

No small project, this plant incorporates many innovative and customized technologies, all integrated to help Kögel produce a truly unique solution.

Along the way, we ran into four challenges in particular:

1. Applying Foam & Film technology to 15×3 meter panels
2. Synchronizing homogenic polyurethane laydown timing with conveyor movement
3. Simultaneously positioning several core panels inside the mold
4. Achieving a closing force 4x higher than standard with a 1500-ton press

Among these, the first two stand out, not only from an engineering standpoint, but because Kögel aimed at introducing a novelty to the market: an aesthetic panel that replaces the trailer’s conventional steel top layer and help greatly reduces its overall weight.

Handling such large film surfaces requires a dedicated unwinding and thermoforming system capable of maintaining a flawless finish — without wrinkles. Additionally, achieving perfect synchronization between PUR laydown and the conveyor’s multi-directional motion was crucial: even a one-second mismatch would compromise the panel’s quality.

Delivered in 2025, this plant is fed by two 3-component mixing heads with NoWave injectors and two customized dosing units — designed specifically for Kögel’s sandwich insulation panel application.

The innovative multi-function mold features a mobile frame and vacuum system that thermoforms the film without creating wrinkles on the upper and lower half-molds. The mold can automatically adjust to create panels with different heights. Furthermore, it is possible to create additional versions with different thicknesses and internal rail layouts.

To place the different core panels, we developed a picking system that utilizes the porous structure of the fiberglass mats to lift and position them without damage.

This plant will produce side and roof panels crucial to the cold chain for transporting food, medical supplies, and everyday goods across Europe. These new LITESHELL panels reduce overall trailer weight by about 700kg — a 9% decrease compared to the current Kögel Cool model.

Foam & Film makes it possible to use the panel as both insulation and an exterior surface that is resistant, lightweight, and aesthetically advanced. The final outcome? Lower fuel consumption, increased range, more payload, and fewer emissions.

• Customized dosing units
• 3-component mixing heads with NoWave injectors
• Multi-functional mold with automatic film thermoforming and adjustable geometry
• Conveyor system designed for synchronized laydown
• 1500-ton press, provided by Manni
• Plant integration, engineering and automation software

Learn more about the KÖGEL COOL LITESHELL here.

Explore our turnkey plants for refrigerated truck walls here.