The provided source material details technical specifications and operational processes for PVC-free foaming board extrusion lines. These systems are industrial manufacturing equipment designed for the production of lightweight, foam-structured boards using polyvinyl chloride (PVC) as the primary raw material. The information focuses on the machinery's design, technical capabilities, and the production process, with no reference to consumer free samples, promotional offers, or trial programmes. This article will therefore present a factual overview of these extrusion lines based solely on the technical data provided.
Overview of PVC-Free Foaming Board Extrusion Lines
PVC-free foaming board extrusion lines are automated systems engineered for the continuous production of foam boards and sheets. The core function of these lines is to transform PVC powder, along with additives, into finished foam boards through a free foaming process. The resulting boards are described as lightweight, heat-insulating, and sound-insulating, with applications in advertising, building decoration, transportation, and industrial contexts.
Multiple manufacturers and models are referenced in the source data, each with specific parameters. For instance, one line is specified to have a final product width of 1220 mm, a thickness range of 2-8 mm, and an extrusion capacity of 400 kg/hr, with an electric load of 170 kW. Another system is noted to be suitable for producing boards with thicknesses between 1-10 mm and widths of 1220, 1560, 1830, or 2050 mm, with a capacity ranging from 100 to 250 kg/h.
A key technical feature highlighted is the adoption of an environmentally friendly calcium-zinc stabilizer programme, which discards common lead-containing PVC formulas. This is presented as a technological advantage for producing high-quality, eco-friendly foam boards. The production process is designed to achieve controlled foaming within a closed mould, resulting in boards with a dense core, good surface softness, and an excellent strength-to-weight ratio.
Technical Design and Process
The extrusion lines are designed to address four primary challenges in PVC foaming material production: foaming portion control, surface quality, density uniformity, and dimensional stability. A core component of the design is the two-stage extrusion configuration. The first-stage main extruder is responsible for the efficient plasticisation, mixing, and preliminary homogenisation of the raw material blend.
The production process begins with the preparation of raw materials. The main components of PVC free foam board are PVC, calcium carbonate (Caco3), a foaming agent, and other additive chemicals. These base polymers are blended with various additives, including blowing agents, stabilizers, colourants, and fillers. The blowing agents are crucial for creating the foam structure within the board.
After thorough mixing, the blended material is fed into an extruder. Inside the extruder, the material is heated to a molten state under controlled temperature and pressure conditions. As the molten material is pushed through the extruder screw, the blowing agents decompose and release gas, causing the material to expand and form a foam-like structure.
The foamed material then passes through a die, which shapes it into the desired board profile. Following the die, the foam board enters a calibration unit. This unit cools and calibrates the board to ensure accurate thickness, width, and surface smoothness. Subsequently, the board goes through a cooling system to fully solidify its structure. Finally, the cooled foam boards are cut to the required lengths by a cutting device and then packaged for distribution.
Common Production Issues and Solutions
The source material identifies common issues that can arise during the production of PVC free foam boards and provides corresponding solutions. These insights are relevant for operators of the extrusion lines.
- Uneven cell structure: This issue can be caused by inconsistent distribution of blowing agents or improper temperature control during extrusion. The recommended solution is to ensure thorough mixing of the raw materials to evenly distribute the blowing agents. Additionally, operators should regularly calibrate and monitor the extrusion temperature to maintain a stable foaming process. Adjusting the screw speed and temperature settings as needed can also help achieve a uniform cell structure.
- Incorrect board dimensions: This may result from inaccurate calibration of the calibration unit or problems with the cutting device. The solution is to regularly calibrate the calibration unit according to the manufacturer’s instructions to ensure the correct thickness and width of the boards.
System Automation and Services
Modern PVC free foam sheet production lines are described as automated integrated systems. The entire process, from the automatic metering, mixing, and conveying of raw materials to extrusion, foaming, shaping, cooling, pulling, cutting, and stacking, is designed to achieve fully automated continuous production.
Manufacturers of these lines often position themselves as process partners rather than just equipment suppliers. They may offer complete solutions and a full set of turnkey engineering services, encompassing production line design, manufacturing, installation, commissioning, and personnel training. Services typically include pre-sale, sales, and after-sales support, guided by principles of integrity, preciseness, excellence, and dedication.
Conclusion
The provided technical data describes PVC-free foaming board extrusion lines as sophisticated, automated manufacturing systems for producing lightweight foam boards from PVC. The key aspects covered include their design for eco-friendly production using calcium-zinc stabilizers, the two-stage extrusion process, the detailed production workflow from raw material blending to packaging, and common operational challenges with their solutions. The information is strictly technical and focuses on industrial machinery capabilities, with no connection to consumer free samples, trials, or promotional offers. The systems are positioned as solutions for efficient and stable production, with manufacturers offering comprehensive engineering and support services.