Project PVC ceiling panel production line for Iran customer

Order time: Feb, 2021.

The customer already has two production lines in his factory. In order to meet the market demand, the customer decided to purchase a new production line.

This time he ordered a production line with SJZ55/120 conical twin screw extruder.

Complete production line includes screw loader, extruder, mold, vacuum calibration table, Haul-offs& cutting machine, stacker.

Extruder motor power: 22kw. Main motor adopts Beide Siemens brand which is made in China, with globe service. Inverter system adopts ABB inverter.

Gearbox is vertical type, it can save the space of factory.

Mold with Infrared tracker, to adjust the different extrusion speed of two sides. Improve production efficiency.

Vacuum calibration table with 4m. It installs blower, which can move the water efficiently.

Haul-offs can work max. 5m/min, cutting system with two type cutting, motor cutting & cylinder cutting.

In terms of our valuable experience and technical improvement, the capacity of production line can reach to 1000Sqm per day.

At the same time, the production line can equip online foil transfer and online lamination.

The plastic buckle plate extruder, as the core equipment for producing PVC, PE, PP and other material buckle plates, adopts a modular combination architecture and is mainly composed of five core systems:

Extrusion system: including high-strength screw and barrel, the screw is made of 38CrMoAlA alloy material, and after nitriding treatment, the hardness reaches HV950 or above, effectively improving wear and corrosion resistance; The material barrel is equipped with a zone heating device with a temperature control accuracy of ± 1 ℃, ensuring uniform plasticization of the raw materials. ​

Feeding system: using a forced feeding machine, the feeding amount can be accurately controlled (adjustment range 5-50kg/h), combined with a raw material drying pretreatment module, to avoid bubbles and cracks on the surface of the product caused by high moisture content of the raw material. ​

Molding system: Customized molds are made of high-quality mold steel, and the mold head flow channel is optimized to ensure smooth melt flow. It can adapt to the molding needs of different specifications (width 200-600mm, thickness 0.8-3.0mm) of buckle plates, and the mold replacement time is ≤ 30 minutes. ​

Cooling and shaping system: including a vacuum adsorption shaping box and an air cooling device, with adjustable vacuum degree (-0.06~-0.09MPa), ensuring rapid cooling and shaping while ensuring the flatness of the buckle surface and dimensional accuracy (± 0.1mm) meets the standard, avoiding warping and deformation. ​

Traction and cutting system: Adopting a variable frequency speed control traction machine, the traction speed is continuously adjustable from 0.5-5m/min, equipped with a high-precision servo cutting device, the cutting length error is ≤± 2mm, and it supports fixed length cutting and automatic counting functions. ​

Working principle: Integrated process from raw materials to finished products

Raw material pretreatment: PVC resin powder, stabilizer, plasticizer and other auxiliary materials are mixed evenly according to the formula ratio, and then dried in a dryer (temperature 80-100 ℃, time 2-3 hours) to remove moisture; ​

Melt extrusion: The mixed raw materials enter the material barrel through the feeding hopper, and under the shearing and conveying action of the screw, they are heated in different zones (160-180 ℃ in the front section of the barrel, 170-190 ℃ in the middle section, and 180-200 ℃ in the head) to achieve melt plasticization and form a uniform melt; ​

Forming and shaping: The molten material is extruded into a buckle plate blank through a die head, enters a vacuum shaping box, and rapidly shapes under negative pressure adsorption and cooling water flow, while further cooling is achieved through an air cooling system; ​

Traction cutting: The finalized buckle plate is transported at a constant speed by a traction machine, accurately cut to a preset length by a servo cutting machine, and finally collected by a discharge rack.

Applicable scenarios: Multi domain coverage, outstanding cost-effectiveness

In the field of home decoration and building materials, we produce indoor ceiling panels and wall decoration panels, which have waterproof, moisture-proof, and easy to clean characteristics and are suitable for living rooms, kitchens, bathrooms, and other scenarios; ​

In the field of engineering decoration, it is used for ceiling decoration in public spaces such as office buildings, shopping malls, and hospitals. It can mass produce fire-resistant and flame-retardant buckle plates (with an oxygen index of ≥ 32 after adding flame retardants); ​

Special scenario customization: Through formula adjustment and mold optimization, we produce specialized products such as anti-corrosion buckle plates (suitable for chemical workshops), soundproof buckle plates (suitable for computer rooms and KTVs), and antibacterial buckle plates (suitable for medical facilities). ​

Core advantages: high efficiency, energy saving, easy operation

Efficient production: By adopting optimized screw design and zone temperature control technology, the plasticization efficiency is increased by 20%, and the daily output of a single equipment can reach 2-8 tons, meeting the needs of large-scale production; ​

Energy saving and consumption reducing: equipped with variable frequency energy-saving motors and waste heat recovery systems, the energy consumption per unit product is reduced by 15-20% compared to traditional equipment, and the operating noise is ≤ 75dB

Easy to operate: Equipped with a PLC touch screen control system, it can monitor key parameters such as temperature, pressure, and speed in real time, support parameter storage and one click calling, and beginners can get started with simple training; ​

Stable and durable: The core components are made of high-quality alloy materials and precision machining processes. The equipment has a fault free operation time of ≥ 8000 hours, a long maintenance cycle, and low maintenance costs in the later stage; ​

Flexible adaptation: Modular design supports rapid mold replacement and formula adjustment, and can produce buckle products of different materials, specifications, and colors, adapting to diverse market demands.