Real Panel’s manufacturing facility in Turkey produces the full range of insulated sandwich panels — facade, roof, and cold room — that serve industrial, commercial, agricultural, and cold storage construction across Turkey and five export markets. But a factory is more than machines. It is a quality system. Every panel that leaves our production line has passed through eight quality control steps designed to ensure that the declared performance values — thermal, fire, dimensional — are the delivered performance values.
This article takes you inside our Real Panel manufacturing facility to show how sandwich panels are made, how quality is controlled at every stage, and why this matters for your building project. Whether you are an architect specifying panels, a contractor installing them, or a building owner investing in them — understanding what happens behind the factory doors gives you confidence in the product on your building.
On this page:
- The continuous production line — how sandwich panels are made
- Step 1: Steel coil inspection & preparation
- Step 2: Profiling — creating the panel face
- Step 3: Core material injection / placement
- Step 4: Lamination & bonding
- Step 5: Curing — where performance is locked in
- Step 6: Cutting & dimensioning
- Step 7: Quality testing & inspection
- Step 8: Packaging & dispatch
- Certifications that prove our quality
- Production capacity & lead times
- Visit our facility
- Frequently asked questions
The continuous production line — how sandwich panels are made
The Real Panel manufacturing facility operates a continuous production line — one of the most advanced panel manufacturing systems available. Raw steel coils enter at one end; finished, packaged, quality-inspected panels exit at the other. The entire process is automated and computer-controlled, with human expertise focused on quality monitoring, adjustment, and decision-making at each critical stage.
The continuous line produces panels at consistent speed, pressure, and temperature — the three variables that determine panel quality. Unlike batch or manual production methods, continuous-line manufacturing eliminates the human variability that causes panel-to-panel quality differences. This is why the Real Panel manufacturing facility can guarantee that every panel meets EN 14509 performance requirements — because the process, not the operator, controls the outcome.
Step 1: Steel coil inspection & preparation
Every panel begins as a steel coil. At the Real Panel manufacturing facility, incoming coils are inspected for:
- Coating quality: Polyester, PVDF, plastisol, or stainless steel — coating thickness and adhesion are verified against supplier certificates.
- Steel gauge: 4 mm, 0.5 mm, or 0.6 mm — measured and documented.
- Surface condition: Scratches, dents, or coating defects are identified before processing. Damaged coils are rejected.
- RAL color verification: Color match is checked against RAL standard charts. Consistent color across a project requires consistent incoming material.
Only coils that pass all four checks enter the production line. Rejected coils are returned to suppliers — quality begins before manufacturing starts.
Step 2: Profiling — creating the panel face
The steel strip is fed through the profiling rollers that shape the panel face — flat, micro-rib, or trapezoidal depending on the production run. At our Real Panel manufacturing facility, profile change takes approximately 30 minutes, allowing efficient switching between product types. The profiling process creates the panel’s characteristic surface pattern while maintaining precise dimensional control across the full panel width (up to 1150 mm).
Step 3: Core material injection / placement
This is where the panel’s insulation performance is created:
- PUR / PIR panels: Liquid polyurethane or polyisocyanurate chemicals are injected between the moving steel facings. The mixture expands and bonds to both steel surfaces simultaneously.
- EPS panels: Pre-cut expanded polystyrene blocks are placed between the facings and bonded with adhesive under heat and pressure.
- Rockwool panels: Pre-cut stone wool slabs (mineral fiber, factory-produced by specialist suppliers) are placed between facings and bonded.
At our Real Panel manufacturing facility, PUR/PIR injection parameters — chemical ratio, temperature, volume, speed — are computer-controlled to ensure consistent foam density throughout every panel. Foam density directly determines lambda (thermal conductivity) — inconsistent density means inconsistent insulation performance. Our system eliminates this risk.
Step 4: Lamination & bonding
The steel-foam-steel sandwich passes through the lamination press — a continuous double-belt press that applies controlled pressure and heat. This step bonds the insulation core permanently to both steel facings, creating the composite sandwich structure that gives panels their structural strength. At the Real Panel manufacturing facility, press parameters are monitored in real-time: pressure uniformity, temperature distribution, and belt speed are all logged for traceability.
Step 5: Curing — where performance is locked in
For PUR and PIR panels, the curing phase is where the foam reaches its final density, cell structure, and thermal performance. The panel passes through a temperature-controlled curing zone where the chemical reaction completes. At our Real Panel manufacturing facility, curing parameters are optimized for each core type — PUR and PIR have different optimal curing profiles. Under-curing produces soft, low-density foam with poor thermal values. Over-curing wastes energy and can cause surface defects. Our automated system delivers the exact curing profile every time.
Step 6: Cutting & dimensioning
The continuous panel strip is cut to the specified length by an automated flying saw that synchronizes with line speed — no stopping, no waste from miscuts. At our Real Panel manufacturing facility, cutting tolerances are ±1 mm on length — essential for projects where panels must fit precisely between structural members. Each panel is measured and length-verified automatically before proceeding to inspection.
Step 7: Quality testing & inspection
This is the quality gate at our Real Panel manufacturing facility. Every production batch is tested for:
| Test | What it measures | Standard |
|---|---|---|
| Thickness measurement | Panel meets specified mm ±tolerance | EN 14509 |
| Adhesion / peel test | Core-to-facing bond strength | EN 14509 |
| Density check | Foam core density = declared value | EN 14509 |
| Lambda verification | Thermal conductivity = declared λ | EN 12667 |
| Dimensional accuracy | Length, width, squareness | EN 14509 |
| Surface inspection | Coating quality, no defects | Visual + instrument |
| Fire test reports | Euroclass rating verified | EN 13501-1 |
| Compressive strength | Load-bearing capacity | EN 826 |
Panels that fail any test are quarantined and investigated. They do not ship. This zero-compromise quality gate is what separates a certified manufacturer from a low-cost producer. At our Real Panel manufacturing facility, quality is not a department — it is the production line itself. See our quality policy and test reports.
Step 8: Packaging & dispatch
Finished panels are stacked, edge-protected, and wrapped in protective film at the Real Panel manufacturing facility. Packaging is engineered for the delivery method:
- Domestic (Turkey): Standard truck loading with edge protectors and strapping.
- Export (Romania, Bulgaria, Georgia, Macedonia, Kosovo): Enhanced packaging for longer transport distances — additional edge protection, moisture-resistant wrapping, and load securing for international freight. Each shipment includes full documentation: CE certificates, fire test reports, packing lists, and customs paperwork.
Our export logistics team coordinates delivery timing with construction schedules — panels arrive when the site is ready to install, not weeks before sitting exposed on site.
Certifications that prove our quality
The Real Panel manufacturing facility holds the following certifications and product approvals, all available for download from our certificates page:
- CE Marking: All products carry CE marking per EN 14509 — mandatory for European market access and accepted in all our export markets.
- EN 14509 compliance: The harmonized European standard for self-supporting insulated panels. Our panels are manufactured to this standard continuously, not just for test batches.
- EN 13501-1 fire testing: All core materials tested and classified. Reports available for every product variant.
- ISO 9001 quality management: Our quality management system is certified to ISO 9001 — covering everything from incoming material inspection to final dispatch.
- Manufacturing consistency: Continuous production line with automated parameter control ensures every panel matches the declared performance. No batch-to-batch variation.
For building permit applications in Romania, Bulgaria, Georgia, Macedonia, and Kosovo, our CE documentation package provides everything required for regulatory approval. Learn about our manufacturing standards and sustainability approach.
Production capacity & lead times
| Metric | Value |
|---|---|
| Production line type | Continuous double-belt press |
| Panel types | Facade (micro-rib, flat), Roof (trapezoidal), Cold Room (cam-lock) |
| Core materials | PUR, PIR, EPS, Rockwool |
| Panel width | Up to 1150 mm |
| Panel length | Custom — up to 12,000 mm |
| Thickness range | 30 mm to 200 mm |
| Steel facing range | 0.4 mm to 0.6 mm |
| Typical lead time (domestic) | 2-3 weeks from order confirmation |
| Typical lead time (export) | 2-4 weeks production + delivery time |
For project-specific lead times and production scheduling, contact our sales team. Large export orders can be coordinated with phased delivery to match construction progress.
Visit our facility
We welcome architects, contractors, developers, and building owners to visit the Real Panel manufacturing facility. Seeing the production line, quality testing, and packaging process in person gives you the confidence that comes from knowing exactly how your building materials are made. To arrange a factory visit, contact us or reach out through our locations page.
Cannot visit in person? Our virtual factory tour video shows the complete production process in three minutes. For detailed product information, browse our product catalogs or use the interactive Panel Selector to find the right panel for your project.
Ready to specify Real Panel products?
Now that you have seen inside our Real Panel manufacturing facility, put that quality to work on your project. Request a free quote through our Quote Request Form. Share your project details — we respond within 24 hours with panel recommendations, pricing, and delivery scheduling.
Explore by application: Industrial · Commercial · Cold Storage · Food & Pharma · Logistics · Agriculture.
Explore by need: Thermal · Fire · Acoustic · Hygienic.
Read more: How to choose the right core material · Sandwich panel pricing guide.
Frequently asked questions
What types of sandwich panels does the Real Panel manufacturing facility produce?
Our Real Panel manufacturing facility produces three main panel types: facade panels (flat, micro-rib profiles), roof panels (trapezoidal profile), and cold room panels (cam-lock system). All are available with PUR, PIR, EPS, or rockwool cores, and in a full range of steel thicknesses, surface coatings, and RAL colors. Browse our complete product range.
Are Real Panel products CE certified?
Yes. All products from our Real Panel manufacturing facility carry CE marking per EN 14509. Fire classifications are tested and certified per EN 13501-1. CE documentation is provided with every shipment for building permit applications. View our certificates.
What is the typical production lead time?
Standard production lead time at our Real Panel manufacturing facility is 2-3 weeks from order confirmation for domestic Turkey delivery, and 2-4 weeks production plus delivery time for export markets (Romania, Bulgaria, Georgia, North Macedonia, Kosovo). Large or complex orders may require additional scheduling coordination.
Can I visit the Real Panel manufacturing facility?
Yes. We welcome factory visits from architects, contractors, developers, and building owners. Seeing the production line, quality testing, and packaging gives you firsthand confidence in our manufacturing quality. Contact us to arrange a visit.
Does Real Panel export to my country?
We currently export to Romania, Bulgaria, Georgia, North Macedonia, and Kosovo, with full logistics coordination and customs documentation support. Request a quote for your export project.