PP PE ABS Thick Solid Board Machine Line

A complete equipment production line for thick sheets of PP, PE, and ABS.

This is a technologically mature and highly integrated extrusion production line used for producing plastic sheets with thicknesses typically ranging from 2mm to 15mm or even thicker. These boards are widely used in advertising printing, food packaging, industrial liners, building templates, refrigerator liners, automotive interiors, and other fields.

 

PP thick board

 

PP thick board

PP thick board

PP thick board

A complete thick sheet production line mainly consists of the following parts:

1. Extrusion system

This is the "heart" of the production line, responsible for plasticizing plastic raw materials into a uniform melt.

·Extruder:

·Type: Single screw extruder is usually used, and twin-screw extruder is also used for occasions with high production and mixing requirements.

·Specification: Select the screw diameter (such as Φ 90mm, Φ 120mm, Φ 150mm) and length to diameter ratio (L/D usually at least 32:1, commonly 35:1) based on the width and thickness of the board. For sensitive materials such as ABS, the screw design should be gentler (compression ratio should not be too high) to prevent degradation.

·Screw design: In response to the different melting characteristics of PP/PE/ABS, the compression and metering sections of the screw will be specially designed.

·Network changer:

·Function: Filter impurities and carbide materials in the melt to ensure the quality of the board. Continuous screen changers (such as double column and mesh belt) are standard for thick sheet production, as the cost of production interruption (replacing the filter) is very high.

·Gear pump (optional but highly recommended):

·Function: Installed between the extruder and the mold. It can stably output molten materials with extremely high pressure, completely eliminating thickness fluctuations caused by screw pulses. It is a key equipment for producing high-end thick plates, especially PP and ABS plates with high optical requirements, and can significantly improve thickness accuracy.

·Sheet metal mold:

·Type: Hanger style T-shaped die is the absolute mainstream choice.

·Material: High grade alloy steel, with precise calculation and processing of internal flow channels to ensure uniform flow velocity and pressure of the melt across the entire width of the mold lip.

·Mold lip adjustment: Equipped with a belt or push bolt fine adjustment mechanism, the mold lip opening can be finely adjusted manually or automatically to control the lateral thickness deviation of the board.

·Heating method: Usually using cast copper heaters or tube heaters, with precise temperature control in different zones.

2. Forming and cooling system

This is the key to determining the flatness and surface quality of the board.

·Three roll calender:

·Function: This is the core forming device of the thick plate production line. The molten slab coming out of the mold immediately enters the gap between the three rollers, is rolled, cooled, and shaped, and obtains a shiny surface.

·Structure: Usually composed of three rollers: upper, middle, and lower. The inside of the roller is a double spiral flow channel, which is filled with constant temperature oil for precise temperature control.

·Roller arrangement: There are upright, horizontal, and 45 ° angled types. The 45 ° oblique angle is the most common because it facilitates the natural extension of the melt and reduces internal stress.

·Medium height compensation: Due to the slight deformation of the roller under pressure, the lower roller is usually ground to have a certain "medium height" (convexity) to compensate for the deformation and ensure uniform thickness of the rolled sheet.

·Roll gap adjustment: Each roll gap can be independently electrically or hydraulically adjusted to adapt to different sheet thicknesses.

·Cooling conveyor frame:

·Function: Further cool the preliminarily formed three roll board to room temperature.

·Structure: Composed of multiple groups (usually dozens) of passive or actively driven rollers. There is an auxiliary pressure roller above to prevent the board from warping.

·Cooling method: natural cooling or supplemented with air cooling.

3. Traction and cutting system

·Traction machine:

·Function: Provide stable traction to smoothly guide the board out of the three rollers and cooling frame. Usually, it is one or more pairs of rubber or silicone rollers, and the upper roller can be pneumatically pressed down.

·Automatic cutting/stacking device:

·Tracking type cutting saw: During cutting, the saw table synchronously tracks the movement speed of the board, returns to its original position after cutting, and achieves fixed length cutting with a smooth cut.

·Stacker crane: automatically receives cut boards and stacks them neatly. Automated stacking is crucial for heavy boards.

4. Auxiliary system

·Feeding system: Vacuum suction machine, which transports raw materials from the silo to the extruder hopper.

·Mixing machine: If color masterbatch or other additives need to be added, they need to be pre mixed evenly with a mixing machine first.

·Hydraulic system: provides power for screen changers, mold adjustments, etc.

·Temperature control system: provides precise heating and cooling for extruders, molds, and three rollers (oil temperature machine, water temperature machine).

·Electrical control system: a centralized control system based on PLC and touch screen, integrating all motor drives, temperature control, parameter settings, and fault diagnosis.

·PP (polypropylene):

·Crystalline materials have a high cooling shrinkage rate.

·Process key: Three roll temperature control is very important. The roller temperature should not be too low, otherwise the board will become brittle due to rapid crystallization, and the internal stress will be high, making it prone to warping in the later stage. Usually, a higher roller temperature (such as 80-100 ° C) is required for slow cooling.

·Surface treatment: The surface of PP board is non-polar. If printing or bonding is required, a corona treatment machine can be integrated at the back of the production line.

·PE (polyethylene):

·Especially HDPE, with high crystallinity and high melt viscosity.

·Process key: Similar to PP, attention should be paid to the cooling process to prevent warping. The processing temperature range is wide.

·ABS (acrylonitrile butadiene styrene copolymer):

·Amorphous materials are highly sensitive to temperature, prone to degradation and yellowing.

·Process key:

·Processing temperature: Strictly control the temperature of each section to prevent overheating. Screw design should avoid excessive shear heat.

·Cooling: As an amorphous plastic, ABS has a lower cooling shrinkage rate than PP/PE, but requires extremely high smoothness for the three rollers to achieve a high gloss surface.

·Drying: ABS raw materials must be thoroughly dried in advance! Usually, it needs to be dried at 80-85 ° C for 3-4 hours or more, otherwise the board will produce bubbles or water marks.

Raw materials → Drying (ABS required) → Extruder plasticization → Filter with screen changer → Gear pump stabilization (optional) → Mold forming → Three roll calendering and shaping → Cooling and conveying → Traction → Fixed length cutting → Stacking → Finished product

If you need to consider purchasing or evaluating such equipment, you should pay attention to:

1. Production capacity and board specifications: Clearly define the maximum/minimum width, thickness range, and target production capacity (kg/h) of the required boards.

2. Brand and quality of core components: The manufacturing level and accuracy of extruders, gear pumps, molds, and three rollers directly determine the quality of the sheet metal.

3. Control level: The higher the degree of automation, the easier the operation, and the more stable the product quality (such as automatic thickness measurement feedback system).

4. Manufacturer experience: Prioritize suppliers with successful PP/PE/ABS thick plate cases.

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