TECHNOLOGY
Industrial thermoforming. The alternative to fibreglass.
Beyonder manufactures isothermal panels using a process completely different from hand-laid fibreglass. Vacuum-thermoformed ABS, high-density polyurethane foam, automated assembly. The result: superior thermal performance, consistent quality, recyclable material.
THE PROCESS
From ABS granule to finished panel. No hands.
Two of Europe's most advanced automated thermoforming lines. Every panel is vacuum-formed, bonded with PU foam, and trimmed with millimetre precision. No manual intervention in the production cycle.
Vacuum thermoforming
The ABS/PC sheet is heated and vacuum-formed onto the vehicle-specific mould. Precise geometries, uniform thickness, guaranteed repeatability.
Polyurethane foam injection
High-density PU foam is injected between the two thermoformed sheets. Controlled expansion for a consistent K = 0.30 coefficient on every panel.
Trimming and assembly
Precision CNC cutting, automated quality control, full traceability. Every panel leaves the line identical to the last.
K = 0.30
Thermal coefficient
25% beyond the ATP reinforced threshold (K ≤ 0.40). Best in class.
-50%
Installation time
Compared to the fibreglass industry standard
100%
Recyclable
ABS fully recyclable at end of life
0
Panel-to-panel variance
Automated production: every panel identical
ABS vs GRP
Why thermoformed ABS outperforms fibreglass
Fibreglass (GRP) has dominated the market for decades. But its structural limitations are well known to anyone managing an isothermal fleet. Thermoformed ABS solves every one of them.
Production process
Beyonder ABS
Automated, repeatable
GRP
Manual, artisanal
Thermal coefficient
Beyonder ABS
K = 0.30 (consistent)
GRP
K = 0.35 - 0.45 (degrades)
Delamination
Beyonder ABS
Impossible: monolithic panel
GRP
Common over time
Moisture absorption
Beyonder ABS
Zero
GRP
Progressive (micro-cracks)
Impact resistance
Beyonder ABS
High, elastic
GRP
Brittle, cracks
Interior surface
Beyonder ABS
Smooth, non-porous, HACCP compliant
GRP
Porous, hard to sanitise
Recyclability
Beyonder ABS
100% recyclable
GRP
Not recyclable (landfill)
Production emissions
Beyonder ABS
Zero carcinogenic emissions
GRP
Glass fibre dust
Traceability
Beyonder ABS
Complete, panel by panel
GRP
Limited or none
Installation time
Beyonder ABS
50% faster
GRP
Industry standard
CERTIFICATIONS AND PATENTS
Guaranteed compliance. Protected innovation.
ATP FRCX
International certification for the transport of perishable goods under temperature control. Reinforced Isothermal / Reinforced Refrigerated Class C classification.
HACCP
Smooth, non-porous ABS surfaces compliant with food safety requirements (EU Reg. 852/2004, 853/2004). Easy to sanitise.
ISO 9001
Certified quality management system. Standardised processes, documented quality control, continuous improvement.
Industrial patents
Patent portfolio for the thermoforming process applied to isothermal insulation. Coverage: Italy, Switzerland, WIPO international application.
GALLERY
From the production line to the finished vehicle
Want to see the technology up close?
We arrange technical visits at our Palomonte (SA) facility in Italy. Or contact us for a free technical consultation.
Book a visit