PVC WPC Foam Board Extrusion Machine Line

PVC (polyvinyl chloride) and WPC (wood plastic composite material) foam board equipment.

This is a sophisticated and highly specialized extrusion production line, which is used to produce lightweight, heat insulation, sound insulation and easy processing foam plastic plates. PVC foam board (such as Celuka process for free foaming/skin foaming) and WPC foam board are widely used in industries such as construction, advertising, furniture, and decoration.

 

PVC foam board

 

PVC foam board

PVC foam board

PVC foam board

1. PVC foam board:

·Process: The Celuka method is mainly used, which involves skin foaming. The mold outlet has a shaping die (commonly known as a "mouth die" or "plate die"), where the molten material is extruded under high pressure and enters an environment with a sudden drop in pressure. The internal foaming agent vaporizes, but the outer skin quickly cools down in contact with the inner wall of the shaping die, forming a hard, smooth, and dense layer of crust.

·Features: The surface is very smooth and hard, and the interior is closed cell foam structure, with light weight and high strength.

2. WPC foam board:

·Process: Mix wood powder (or plant fibers such as bamboo powder and rice husk) with plastic (mainly PVC, PE, PP) and extrude them into shape. Foaming can significantly reduce the density of the board, increase toughness, and improve appearance (with a stronger woody feel).

·Features: Combining the advantages of wood and plastic, it has higher hardness than pure plastic, and is more resistant to moisture and corrosion than wood. After foaming, it becomes lighter and more cost-effective.

A complete PVC/WPC foam board production line is a model of "one machine, two lines", where one production line simultaneously completes the two major processes of plasticization and shaping. It mainly consists of the following systems:

1. Mixing and conveying system

·High speed hot and cold mixers:

·This is an absolutely necessary pre-treatment equipment for PVC production. PVC resin is in powder form. It needs to be fully mixed, infiltrated and gel with more than ten additives, including stabilizer, foaming agent (AC series, etc.), modifier, lubricant, wood powder (for WPC), pigment, etc. at high temperature (about 120 ℃), and then cooled to 40-50 ℃ in the cold mixer to prevent caking.

·The mixing quality directly determines the performance and foaming quality of the final product.

2. Extrusion system

·Conical twin-screw extruder:

·This is the absolute mainstay of PVC/WPC extrusion. The design of the conical screw is very suitable for processing powdered PVC dry mixtures. It has strong feeding capacity, relatively low shear heating, and good mixing and plasticizing effects on materials.

·Specifications: Common models such as STS-55, STS-65, STS-80, etc., with output ranging from 100kg/h to 600kg/h.

·Foaming agent injection system (for chemical foaming):

·The foaming agent (AC) has been added during the mixing process. No additional equipment is required.

·Foaming agent injection system (for physical foaming):

·If supercritical CO ₂ or N ₂ is required as a physical foaming agent, a precise gas metering and injection system is needed to inject the supercritical fluid into the melt.

·Mold:

·Foam board molds are the core of technology and extremely precise.

·Adopting a hanger style flow channel design ensures absolute uniformity of pressure, flow rate, and temperature when the melt exits the mold, which is a prerequisite for obtaining a uniform pore structure and stable density distribution.

·There is a throttling device inside the mold to establish back pressure.

·The mold export is a standardized mouth mold that matches the shape of the sheet metal.

3. Forming and cooling system (the biggest difference from solid board production line)

·Vacuum shaping table:

·This is the key equipment of the Celuka method. The initially foamed slab coming out of the mold immediately enters one or more vacuum forming boxes.

·There are upper and lower shaping plates inside the shaping box, which are cooled by water. By vacuum adsorption, the soft slab is tightly adhered to the cooling and shaping plate, resulting in precise dimensions, smooth surface, and crust structure.

·The length and number of sections of the shaping table directly affect the production speed and cooling effect.

·Cooling water tank:

·After initial cooling and shaping on the shaping table, the board enters the cooling water tank for final cooling. The sink is usually a floating ball or roller type to avoid deformation of the board.

4. Traction and cutting system

·Traction machine:

·Adopting a multi roller type (with multiple rubber rollers at the top and bottom) or a track type tractor. Provide strong, stable, and uniform traction to overcome the vacuum adsorption resistance inside the shaping table and smoothly pull out the board.

·Automatic cutting saw:

·The tracking cutting saw is a standard configuration. During cutting, it moves synchronously with the board to achieve stress free cutting and ensure a smooth and even cut.

·Stacker crane/flipping platform:

·Automatically receive and stack sheets. For large-sized foam boards, automated stacking is essential.

5. Auxiliary system

·Vacuum system: provides stable vacuum degree for the shaping table.

·Water circulation system: provides cooling water for extruders, molds, shaping tables, and cooling water tanks.

·Temperature control system: Accurately control the temperature of each section, mold, and shaping plate of the extruder.

·PLC control system: Integrated control of all motor, temperature, vacuum degree, speed and other parameters.

PVC foam board (using Celuka method as an example): PVC resin+additives+foaming agent → high-speed hot mixing → cold mixing → plasticization by cone double extruder → mold extrusion → entering the vacuum setting table for skin forming and foaming shaping → cooling water tank → traction → fixed length cutting → stacking → finished product

WPC foam board: Wood powder drying → Mixing with PVC/PE/PP resin and additives → (granulation or direct use) → Cone double extruder plasticization → .. (The subsequent process is basically the same as PVC foam board)

1. Formula is the soul: The formula of foam board is extremely complex, and the balance between foaming agent, lubricant, and stabilizer is crucial. Excellent equipment suppliers must provide mature formula technology and process guidance.

2. The mold and shaping table are the core: the design of this system directly determines the density, surface quality, thickness uniformity, and production stability of the board. Its processing accuracy requirements are very high.

3. Temperature control is the lifeline: the foaming process is extremely sensitive to temperature. Excessive temperature can lead to excessive foaming and cell rupture; Low temperature can lead to insufficient foaming and rough surface. The temperature of the entire extrusion and shaping process must be precise and stable.

4. Choose an experienced supplier: The debugging and process exploration of the foam board production line are very professional. Be sure to choose equipment manufacturers with a large number of successful cases and strong technical support.

5. Clarify product positioning: Before purchasing, it is necessary to clarify the target product (thickness, width, density), production capacity, and main raw materials (whether PVC or PE/PP based WPC), so that equipment manufacturers can provide the most suitable solution.

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