Advantages of Automatic Batch EPS Pre-expander
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Automatic batch EPS pre-expander is a kind of equipment which can automatically complete the procedures of measuring, loading raw material, heating, expanding and discharging. It is an ideal equipment for large and medium enterprises to produce light foamed products. The advantages of automatic batch EPS pre-expander are as follows:
-It is much faster than manual expanding, which means that you can produce more products in a shorter amount of time.
-It is very consistent, so you can be sure that each product will be the same as the last one.
-It is less labour intensive, so you will not need to hire as many staff to operate it. Overall, using an automatic batch EPS pre-expander can help to improve your business in a number of ways. If you are thinking about investing in one, then these are just some of the advantages that you can expect.
1. The whole process is controlled by computer, which is easy to operate;
2. The structure of the machine is reasonable and the performance is stable;
3. The heating system adopts hot air cycle heating, which can save energy and improve production efficiency;
4. Fully closed expansion chamber and efficient filter system can reduce pollution and improve working environment;
5. Pneumatic discharge door design can realize fully automated production line operation.
The EPS Pre-Expander is a batch type machine that automatically expands raw material beads (EPS/EPP) through steam heating, and is widely used as the first step in the production process of expanded bead products. The pre-expander is a key machine in the entire production line, and its performance directly affects the product quality and production efficiency of the whole line.
Types of Automatic batch EPS pre-expander
machines There are two main types of EPS pre-expanders: - Continuous pre-expanders - Intermittent pre-expanders Continuous EPS pre-expanders are always in operation, meaning they can operate 24 hours a day, 7 days a week. The EPS beads are continuously fed into the machine and expanded in a controlled manner. These machines are generally used for high volume applications.
Intermittent EPS pre-expanders are only operated when needed. The EPS beads are fed into the machine and expanded in a batch process. These machines are generally used for lower volume applications or when there is a need for more flexibility (e.g., different bead sizes).
EPS is widely used as building insulation material, but it is also used for many other purposes, such as packaging and flotation devices. It is a lightweight, rigid foam that has excellent thermal insulation properties.
EPS is made from expanding polystyrene beads. The beads are expanded with steam and then molded into the desired shape. There are two types of EPS pre-expanders: batch and continuous. Batch pre-expanders are the most common type.
They expand the beads in batches in a separate chamber before they are fed into the molding machine. Continuous pre-expanders expand the beads as they are fed into the molding machine.
Tips for choosing Automatic batch EPS pre-expander
machine Here are some tips that may help you choose the right Automatic batch EPS pre-expander machine for your needs:
1. Know the different types of machines. There are two main types of EPS machines, namely, the automatic and semi-automatic machines. Each has its own set of advantages and disadvantages.
2. Consider the capacity of the machine. The capacity of the machine should be able to accommodate your production volume. If you have a small business, a semi-automatic machine may suffice. On the other hand, if you have a large-scale business, an automatic machine would be ideal.
3. Consider the features of the machine. The features of the EPS pre-expander will determine its efficiency and productivity. Some features to look for include automatic loading and unloading system, foam density control, temperature control, and others.
4. Consider the price of the machine. The price is usually determined by its features and capacity. Compare prices from different suppliers before making a purchase.
About EPS Molding Machine Supplier
China Longwell is a professional EPS Machinery Supplier and polystyrene machine manufacturer, We offer kinds of EPS machines, EPS molds, 3D panel machines, sandwich panel machines, assistant facilities and all kinds of EPS machine spare parts.
For more product information about YouTube information of foam cutting machine manufacturers, you can click on the relevant link below.
Hangzhou Fuyang Longwell Industry Co.,Ltd
Zhenyou Machinery is the largest manufacturer of EPS Shape Molding Machine in northern China. The EPS moulding machines are superior in performance, high in production efficiency, very low failure rate, and are recognized by many customers in both China and International market. Zhenyou Machinery provides various types of EPS Shape Molding Machine for foam box packaging, ICF blocks, etc. If you are interested, We can provide you with the best EPS Moulding Machine solution. Welcome to contact us.
Three EPS machine builders showed transportable “kit-in-a-box” molding plants. Hirsch’s system at Mississippi Green Built is the first in the U.S., making post-Katrina housing for New Orleans.
Kurtz delivered the first mobile pre-expander, containerized with water processing and steam generation in one half and the pre-expander, air compressor, and refrigerating dryer in the other half.
Hirsch built the world’s largest shape molder four years ago to mold EPS into entire wall sections around steel studs and window and door frames. Platen size is up to 8 x 4 m.
Kurtz’s Rotax has two rotating mold halves that mate with a standard moving mold half. This allows loading inserts and demolding parts while another part is being molded.
Alessiotech’s patented double-glazing process melts the surface beads on two sides of an EPS part for a completely waterproof finish. Most parts are glazed only on one side.
Erlenbach builds the only shape molder with high-speed electric servo-driven mold opening. It’s synchronized with a robot that loads inserts and removes and stacks parts.
Infra’s new process takes a slice of block-molded EPS, laminates it (without adhesive) to PVC film and post-forms a surface pattern for interior trim like ceiling tiles and cove moldings.
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Three machine builders at the K Show in Germany last October displayed new transportable “kit” factories for EPS shape molding. Hirsch of Austria, Promass of Italy, and Kurtz of Germany developed molding-plants-in-a-box that can make ICF blocks at a construction site or for rapid reconstruction after natural disasters.
Mane Electricals of India addressed the market for rapid construction of shelters with a giant shape-molding machine capable of making single panels for cast concrete walls, floor, and ceiling of a 10 x 10 ft shelter that can be built in 4 hr.
Kurtz also showed new rotating tools for EPS and EPP designed for faster cycles and more complex parts. And Alessiotech of Italy showed the first dual-sided “glazing” or “crystallizing” of EPS shapes. Glazing one surface of EPS and EPP is a European technology that emerged about 10 years ago for ceiling and roof tiles and is virtually unknown here.
Two of the new transportable shape-molding plants are free-standing, fully equipped factories that can be disassembled and packed in shipping containers, complete with an “erector-set” enclosure. A third mounts all the equipment on skids but assumes rental of an empty plant.
Hirsch Maschinenbau GmbH built its first such plant last year for Mississippi Green Built in Lumberton, Miss., which molds ICF blocks and roof and ceiling panels as part of hurricane reconstruction for New Orleans. The plant has capacity for about 1 million ICF blocks a year. It includes a 2000-sq-ft building, one pre-expander, two large shape-molding presses, a shrink-wrapper, and two utility containers for the steam boiler, water treatment, air compressor, and water cooling.
To minimize floorspace, the system processes beads immediately after pre-expansion instead of storing them in a silo for the conventional 6- to 8-hr aging to dry before molding. Such “direct processing” has been done before, but the problem is moisture on the beads. Hirsch addresses this with its dry vacuum process. All systems are electronically linked, so the two molding machines communicate with the pre-expander and call for material as needed. If molding slows down, the pre-expander draws less material.
The plant takes three weeks to set up or knock down and packs into 12 containers. It also requires a 3000-sq-ft concrete pad, but a parking lot will do. Another moveable plant is being installed now on São Tome island off Gabon in equatorial Africa, to build a resort for cruise liners, a hotel, hospital, and school. Hirsch has a demo moveable plant in Austria for customer trials.
Promass Srl installed its first moveable plant in Iran last year. It consists of a 2500-sq-ft building with one pre-expander, bead storage for aging, and two shape-molding machines. Both are equipped with a patented automatic mold-change system, robotic insert feeding, and automatic parts unloading. The plant took three weeks to install. It’s making ICF blocks for a large housing project that will be completed this year. “After that, the complete plant will move to a new location,” says Promass sales manager Gianluca Bazzica. “To take it down will require at most two weeks.”
Kurtz has a different approach. It assumes that it’s easier to rent an empty building than to bolt a factory together and take it apart again. So Kurtz’s moveable plant consists of containerized equipment but doesn’t include a building to house it. Kurtz has sold one complete moveable EPS shape-molding plant, which went to the U.K. in 2005.
Kurtz’s equipment can be supplied either in containers or on platforms and takes two to three weeks to set up or take down. Piping is pre-assembled in sections for fast installation. Steam condensate is trapped at each individual shape-molding machine with a pump to move the water to a cooling tower.
Another containerized option from Kurtz is a complete pre-expander with water processing and the steam boiler in one half, separated by a wall from a VSD 700 batch pre-expander, compressor, and refrigerating dryer in the other half. The container has ventilation to prevent explosion, as well as frost monitors and a small electrical heating system that warms the container automatically when the temperature gets too low, to prevent water pipes from freezing in winter. A target market for the mobile pre-expander is water-treatment plants, which use a floating layer of EPS beads to trap odors.
Mane Electricals in Pune, India (dba Expandable Polystyrene Machinery Export Pvt. Ltd.), claims to have built the world’s largest fully automatic shape-molding machine to produce EPS forms for reinforced concrete building panels for the walls, floor, and roof of a small emergency building. The molding machine has a platen area of 4 x 1.5 meters with a 1.5 m stroke in a 2.5-m-wide frame. The biggest part it can mold is the roof panel—15 x 15 ft x 5 in. thick—and can mold two panels back to back. Cycle time is 3.5 min. The machine also molds EPS panels 10 x 10 ft x 5 in. thick for the floor of the shelter and 12 x 12 ft x 5 in. thick for the walls. Mane built one of the giant machines last year.
It appears, however, that Mane doesn’t hold the size record for EPS shape molding. Four years ago, Hirsch delivered a machine to a customer in Ireland with a platen size of 8 x 4 meters for molding complete house wall panels. Window and door frames and steel studs are inserted into the mold cavity, which is then filled with EPS. The wall is erected at the job site and clad with stucco or other weatherable material.
Kurtz showed a new rotating-mold system for EPP and EPS. Its Rotax molding technology uses two identical mold halves back-to-back in a rotating frame with a single opposing mold mounted in a conventional moving frame. An operator or robot removes parts and loads inserts into one side of the rotating tool, while the other side is being filled with beads and molding the part. This shortens cycle time dramatically by eliminating the time to unload parts and load inserts. An earlier generation of Kurtz rotary machines used a three-position turntable instead of a rotating mold frame (see Learn More).
Kurtz has built two Rotax machines, the first almost three years ago for EPP automotive parts with inserts. The second is a more complex “double Rotax” system, installed last year in France. The double Rotax indexes the two-sided mold half to mate with two moving mold halves instead of one. This allows EPS of two different densities to be molded onto one part—such as a core of lower-density or recycled EPS overmolded with higher-density virgin EPS. Parts can also be molded with two different colors of EPS.
Another approach to automating the process is using robots. Promass introduced a new robot for ICF production to load plastic film and metal inserts and unload parts. A new quality-checking function has been added to the robot by means of an electronic camera that checks to see that inserts are straight, not warped, and have the right dimensions.
Promass also introduced the first EPP molding machine with automatic mold loading and unloading, adapting its automatic mold-change system for EPS to the more complex hook-ups and heavier molds for EPP. Promass is building the first system, which will be installed later this year in a “lights-out” EPP molding plant in Europe.
Surface “glazing” of expandable-bead parts is a European technology for melting the part surface to form a solid, leak-proof skin. This approach saves the cost of insert molding a separately formed skin. Surface glazing is virtually unknown in North America, though one U.S. toolmaker, D8 Inc., has made EPS tools for glazing for about five years.
Until recently, only one side of the part could be glazed. But Alessiotech built the first molding machine for double-sided glazing of EPP sheet just before the K Show. The two-step process is unique and yields a product with a fully glazed surface, covered with a strong, solid surface layer 0.8 to 1.3 mm thick. Alessiotech hasn’t disclosed the technology or cycle time, but says it does not involve rotating or shuttling mold parts. It’s a two-step process within the mold—first, controlled steam profile and vacuum, then surface heating from two sides at once—all on a standard molding machine. Potential applications include designer furniture, boxes to transport hot or cold food, or any EPS part that’s now made with a skin of thermoformed film.
E. A. Heitz OHG in Germany (represented here by TKM Technology) says it has also “double-plastified” both sides of an EPS perimeter panel for building foundations, so moisture doesn’t get into the concrete. But Heitz hasn’t built a commercial system yet.
Meanwhile, the hot new glazing application of the past 18 months is EPS fish boxes for air transport of fresh fish to the U.S. from farms as far away as Chile. For 10 years, these boxes were made by insert molding HIPS film to provide abrasion and leak resistance.
Alessiotech built its first commercial EPS surface-glazing machine in 2000 for ice-cream boxes (glazed on the inside) and commercialized fish boxes in 2005 (glazed on the outside). Alessiotech maintains that fusing the outside surface is much more difficult than the inside. Fusing either surface means more complex tools to apply steam from only one side and more accurate control of the steam pressure. If steam is applied too fast it closes off the spaces between beads and doesn’t penetrate to the solid crystallized surface. Cycle time is also slower than steaming from two sides. Alessiotech is able to control thickness of the solid surface between 0.8 and 1.1 mm.
Heitz glazed the first fish boxes in 2003. It glazes the inside of boxes by coating the male mold with PTFE so it can overheat the EPS surface (266 to 275 F) without sticking. Steam enters from the non-glazed side. Heitz also added new control features to its pre-expanders and EPS shape-molding machines, including lap-top connectivity and remote diagnostics.
Erlenbach GmbH in Germany displayed an EPP box (10 x 10 x 4 in.) with a glazed inside surface, which Erlenbach says is trickier than glazing the outside surface. Erlenbach also showed a high-density EPP car seat made by a German auto maker with 32 plastic and metal inserts and higher densities (0.07 vs. 0.06 g/cc) in corners for strength. Erlenbach sold its first surface-fusing EPS system in 2004 for ceiling and roof tiles.
A new process and application for block-molded EPS was shown for the first time by Infra EPS Machinery GmbH of Germany. Its patented machine takes a cut section of block foam and post-forms it into interior architectural trim such as ceiling tiles and cove moldings by melting the surface and adding deep 3D texture and even some shape. Infra has sold about 100 machines. A newer version of the process laminates PVC film to the slice of EPS block (without adhesive) while post-forming the texture. Infra has built three of these, all for African customers. Platens are 4.8 x 1.2 m.
Nuova Idropress SpA in Italy introduced an 8 m3 pre-expander, the largest in the world, for filling 8 m3 block molds. For the past decade, the largest pre-expander on the market was Erlenbach’s 6.5 m3 model. Nuova Idropress built two of the PJX 8000D discontinuous pre-expanders last year.
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Wieser Industrieanlagen GmbH in Austria developed a new high-speed, hot-wire block cutter with a 4-meter-long wire in partnership with Viro Packaging Machines of Vrhnika, Slovenia. This system cuts a standard 4 x 1 m EPS block into panels in one-fourth the time needed for a typical 1-meter cutting wire. Weiser installed the first of its new Foamline LWQ-4 cutters in Austria last year to cut up to 40 foam blocks per hour. (A predecessor company, Moldex-Wieser, bought by Hirsch in 1998, developed a similar 4-m hot-wire cutter.)
Teubert Maschinenbau GmbH in Germany (represented here by FE&C Foam Equipment & Consulting) introduced “low-energy” EPS molds that are claimed to cut energy consumption up to 80%. The molds are made of an unidentified plastic material (patent applied for) that permits supplying steam to the beads without heating a large aluminum mold that then must be cooled. Teubert’s first commercial plastic mold is being built now for a European packaging application.
Kurtz introduced a new “Multi-Process” machine with two different steam hook-ups for molding EPS and EPP. It allows either normal vacuum molding or use of Kurtz’s energy-saving LTH (low-temperature horizontal) molds. Introduced over a decade ago, LTH molds speed cycle time and save energy because they are coated with PTFE-like material to insulate them thermally from steam and reduce cooling time. Coated molds are more expensive but consume 70% less steam, Kurtz says.
Erlenbach introduced its largest all-electric, servo-driven EPS molding machine to date. Model EHV-C E 1485/1285 opens a 1.9-m-square molding compartment at 500 mm/sec, so the 800-mm stroke takes only 1.6 sec. The advantage is said to be shorter cycles and up to 80% energy savings vs. hydraulics. Positioning repeatability is also more precise (< 0.1 mm) and synchronized with robotic unloading and part stacking. Maintenance is also lower, the company claims.
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Description
LONGWELL, with over 20 years experience, is one of the largest longwell high performance eps polystyrene styrofoam molding machine manufacturers and suppliers in China. With the help of advanced equipment and technology, all of our products are of high quality and low price. Welcome to buy the cheap customized machine from our factory.
The Production Line
Main advantage:
1. Controlled by PLC and touch screen, easy to operate.
2. With vacuum system creates fast product molding and cooling, while decreasing water content.
3. With multiple de-molding device, it can handle any difficult to de-mold product.
Characteristics:
1. This machine applies PLC and touch screen,advanced moulding technique and can produce various shapes of EPS products.
2. This machine can provide different kinds of foam articles with lower moisture content, high foaming speed and lower consumption of energy.
3. There are four kinds of operating mode (automatic,semi-automatic,pause-startup and manual operation)with safe-guard protective device to ensure safe operation.
4. This machine has microcomputer control and touch screen display. It can function high efficiently under computer control and management with high automation.Simplicity of operation and easy to maintain,it can reduce the labor intensity.
5. This machine applies advanced electrical and hydraulic integration system,which improves the moulding speed,lowers the energy consumption remarkably and reduces the environmental pollution.
6. Hydraulic de-mould mode.
Note:
1. Mould plated coated with Zinc is optional
2. Extension of machine base height is optional
3. Other sizes also available
Item
LWS-1200B
LWS-1400B
LWS-1600B
LWS-1750B
LWS-2200B
Mould Dimension(mm)
1200*1000
1400*1200
1600*1350
1750*1450
2200*1350
Max Produce Size(mm)
1050*850*350
1200*1050*350
1400*1200*350
1550*1300*350
200*1200*350
Stroke (mm)
150~1350
150~1350
150~1350
150~1350
150~1350
Steam
Entry
DN65
DN80
DN100
DN100
DN100
Consumption
5~7kg/cycle
6~9kg/cycle
7~10kg/cycle
8~12kg/cycle
12~15kg/cycle
Pressure
0.5~0.7Mpa
0.5~0.7Mpa
0.5~0.7Mpa
0.5~0.7Mpa
0.5~0.7Mpa
Cooling Water
Entry
DN65
DN80
DN80
DN80
DN80
Consumption
45~130kg/cycle
50~150kg/cycle
55~170kg/cycle
55~180kg/cycle
60~190kg/cycle
Pressure
0.3~0.5Mpa
0.3~0.5Mpa
0.3~0.5Mpa
0.3~0.5Mpa
0.3~0.5Mpa
Compressed Air
Entry
DN40
DN50
DN50
DN50
DN50
Consumption
1.5m3/cycle
1.8 m3/cycle
2 m3/cycle
2 m3/cycle
2.5 m3/cycle
Pressure
0.5~0.7Mpa
0.5~0.7Mpa
0.5~0.7Mpa
0.5~0.7Mpa
0.5~0.7Mpa
Vacuum pump capacity
165m3/h
230m3/h
280m3/h
280m3/h
280m3/h
Cycle time
60~100s
70~140s
80~150s
80~150s
100~150s
Power
10.6kw
14.1kw
16.5kw
16.5kw
20kw
Overall dimension(mm)
4500*1840*2900
4600*2140*3100
5000*2300*3400
5000*2450*3500
5000*3000*3500
Machine Weight
4500kg
5000kg
5800kg
6200kg
7000kg
Packaging & Shipping
Packing: standard exporting package
Shippingport: shanghai/ningbo
Services
1. Value clients, guarantee equipment quality and answer clients' questions anytime and anywhere.
2. Customizing machines according to clients' inquiry , such as different design, different brand parts, different colors, more function,etc.
3. Engineers go to clients' factory in time for installation , training and trial production .
4. More spare parts are given to clients for free to ensure the factory working without suddenly stop.
5. 1 year free warranty, Lifetime technical service support.
If you are interested in any of our products or would like any support from us about your factory or any others, please feel free to contact us. We are looking forward to building long well and friendly business relationships with clients from all over the world.
If you want to learn more, please visit our website advantage of epe foam sheet extrusion line.