Advanced tunnel furnaces for automotive and EV applications. Thermoforming plastic tubes, battery cooling lines, thermally conductive mats and coatings with dynamic airflow heating and chiller-based cooling.
Advanced Tunnel Furnaces for Thermoforming, Coating and Thermal Processing of Polymer Components
KEPKA designs and manufactures industrial tunnel furnaces based on convective heating with dynamic, turbulent airflow, dedicated to advanced thermal processing in the automotive and electric vehicle (EV) industry. Our systems are engineered for continuous thermoforming, controlled heating, coating activation, curing and cooling of polymer and composite components, where process stability, repeatability and scalability are critical.
Unlike static or radiation-dominated solutions, KEPKA tunnel furnaces rely on high-velocity, precisely controlled convection, ensuring uniform temperature distribution around complex geometries and predictable thermal behavior across the entire production length. This approach is essential for automotive applications where dimensional accuracy, stress relaxation and material memory must be tightly controlled.
Thermoforming Technology with Dynamic Airflow
KEPKA tunnel furnaces operate with multi-zone convective heating, in which heat transfer is driven by dynamically regulated airflow rather than direct radiation. This allows efficient heat penetration into thick-walled, multi-layer or reinforced products, including components with metal inserts such as springs or structural reinforcements.
Each furnace is divided into multiple independently controlled heating zones, enabling precise shaping of the thermal profile along the full length of the product. This is particularly important for automotive and EV components, where even minor temperature deviations can lead to deformation, internal stress or long-term reliability issues.
Long-Length Thermoforming Components up to 9 meters
KEPKA tunnel furnaces are available in configurations supporting thermoforming of components ranging from short parts (approximately 1.4 m) to long elements reaching up to 9 meters. This capability makes our systems ideally suited for:
- EV battery cooling lines,
- fuel and vapor lines,
- thermal-management conduits,
- large-diameter or multi-channel plastic tubes.
Dynamic airflow combined with programmable transport speeds ensures that every section of the component receives identical thermal exposure, regardless of its length, geometry or wall thickness.
Thermally Conductive and Functional Materials for EV Batteries
A key application of KEPKA tunnel furnaces is the thermal processing and coating of materials used inside EV battery systems. These include thermally conductive mats and sheets, thermal interface materials (TIMs), coated polymer and silicone foams, expansion-compensation layers, and fire-resistant battery protection materials.
Such products require gentle yet highly controlled thermal treatment, often involving coating activation, curing or stabilization without damaging internal structures. KEPKA tunnel furnaces provide precisely controlled temperature gradients and adjustable dwell times, ensuring stable material properties and repeatable performance in high-volume EV production.
Tunnel Furnaces for Heat-Shrink Processing of Cable and Tube Assemblies
KEPKA also designs and manufactures compact tunnel furnaces dedicated to heat-shrink processing of protective sleeves applied on cables and plastic tubes used in automotive and EV applications. These systems are engineered for precise and repeatable shrinking of heat-shrinkable materials on wiring harnesses, fluid lines and technical polymer conduits.
Our solutions are based on hybrid heating concepts, combining infrared energy for rapid surface activation with dynamic, turbulent convection airflow for uniform heat distribution. This combination ensures fast response, controlled shrink behavior and consistent results without local overheating or material damage.
Compact Design and Single-Operator Operation
KEPKA heat-shrink tunnel furnaces are designed with a small footprint, making them easy to integrate into existing production areas or assembly cells. Thanks to a high level of automation and simplified material handling, the entire process can be operated and supervised by a single operator.
After the dynamic surface heating stage, processed products are automatically transferred to a return conveyor located beneath the furnace, guiding them back into the loading and unloading zone. This closed-loop material flow significantly improves ergonomics and minimizes operator movement.
Coating Activation and Curing of Foams and Technical Mats
In coating and curing applications, KEPKA tunnel furnaces enable uniform activation of binders and coating layers, controlled evaporation of solvents or plasticizers, and stabilization of elastic or compressible materials without collapse or shrinkage. This is especially critical for battery safety components, where material behavior under thermal load directly impacts system reliability and long-term performance.
Materials Processed in KEPKA Tunnel Furnaces
KEPKA tunnel furnaces are engineered for a wide range of thermoplastics, elastomers and composite materials commonly used in automotive and EV applications. These include PA6, PA6.6, PA6.12, PP, PE, PEX, TPU, TPE, silicone-based polymers, fiber-reinforced plastics, as well as multi-layer and coated materials requiring precise thermal conditioning.
Integrated Heating, Cooling and Exhaust Systems
KEPKA delivers tunnel furnaces as complete thermal systems, integrating proprietary turbulent convection heating, chiller-based cooling systems with high-efficiency heat exchangers, and exhaust solutions designed to safely remove plasticizers and volatile compounds released during processing.
This holistic system design protects both the processed material and the equipment itself, ensuring long service life and stable operation even in demanding automotive and EV manufacturing environments.
High Throughput and Industry-Ready Automation
KEPKA tunnel furnaces are available in configurations optimized for short takt times and high-volume automotive production. Advanced PLC control and HMI-based recipe management enable real-time monitoring of process parameters, calculation of cycle times and flexible optimization of production output.
The systems are equipped with production data interfaces and automation architecture compatible with modern Industry-ready manufacturing environments, supporting long-term automotive and EV production programs.
Global Deployment, Efficient Operation and Modular Design
KEPKA automotive and EV thermoforming lines are designed for high operational efficiency with minimal operator involvement. Thanks to advanced automation, recipe-based control and synchronized material handling, a single line can be operated and supervised by a small number of operators while maintaining full process stability and repeatability.
To date, KEPKA has delivered approximately 100 thermoforming lines worldwide, supporting continuous production in automotive and EV manufacturing plants across multiple continents. Our systems operate successfully in China, the United States, Mexico, Tunisia, Morocco, Serbia and across European countries, adapting to local production standards, infrastructure conditions and regulatory requirements.
Each thermoforming line is built on a modular architecture, allowing flexible configuration, transport and fast on-site assembly. This approach significantly shortens installation and commissioning time, enabling rapid start-up at customer locations and smooth integration into existing production environments. Modular design also supports future scalability, upgrades and process extensions as production needs evolve.
With global installation experience, standardized modules and a strong focus on operational simplicity, KEPKA delivers thermoforming systems that are not only technologically advanced, but also easy to deploy, easy to operate and ready for long-term automotive production programs.
Integrated Cooling and Automatic Product Collection
Following the shrink process, components are subjected to controlled fan-assisted cooling, stabilizing the material geometry and locking in the final shape. The return conveyor is positioned at an optimized height, allowing finished products to drop directly into bulk packaging containers without additional handling steps.
This layout supports high throughput while maintaining process simplicity and repeatability.
Energy-Efficient Transport with Porous PTFE Conveyor Belt
Material transport through the furnace is realized using a porous PTFE (Teflon) conveyor belt, selected specifically to minimize energy losses and prevent local heat accumulation. The porous structure allows hot air to flow freely through the belt, ensuring:
- uniform heat exposure from all sides,
- elimination of local overheating or surface melting,
- reduced thermal inertia of the transport system,
- improved overall energy efficiency.
This design is particularly important for sensitive heat-shrink materials and thin-wall polymer components used in automotive wiring and fluid systems.
Applications in Automotive and EV Production
KEPKA heat-shrink tunnel furnaces are applied in the production of:
- automotive wiring harnesses,
- protective sleeves for battery and power cables,
- heat-shrink tubing for fluid and cooling lines,
- polymer-based protective coverings in EV systems.
By combining compact tunnel design, hybrid IR and convection heating, efficient material return flow and energy-optimized transport, KEPKA delivers heat-shrink solutions that are easy to operate, space-efficient and fully aligned with modern automotive and EV production requirements.
