Main

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Process

Dry components are supplied from the raw material warehouse to the workshop according to the recipe
for one 8-hour shift of work. Then polystyrene from bags or big bags is loaded into the mixer feeder
(optional automation of the process is possible). Additional components are poured into the raw material bins,
from where all dry components are loaded into the feeder bins of the gravimetric feed system using vacuum pumps. From there, dry components in accordance with the specified recipe are fed to the twin-screw extruder.
The feed quantity is set by the line operator from a single control panel. Raw materials are fed automatically.

The twin-screw extruder is equipped with heating elements and temperature and pressure sensors. The operating speeds and temperature are controlled automatically according to the parameters set from a single control panel. In the extruder, due to the rotation of the screws, the polystyrene
and components move and mix with gradual heating by electric heaters to a temperature of 200 C0 and transition to a molten state.

At the final section of the extruder, foaming agents are fed into the molten mass under a certain temperature
and pressure (additional equipment can be optionally used to improve the absorption of gases in the melt mass) -
(gases and liquids are fed in accordance with the recipe). The melt mass is thoroughly mixed with foaming agents. The foaming agent feed system consists of: tanks and for long-term gas storage,
booster pumps, flow meter, high-pressure pump, pipeline system, pressure sensors, safety valves.
The amount of gases supplied is set by the line operator from a single control panel, in accordance with
the specified recipe. Gases are supplied automatically.

Then the melt mass passes through the connecting element into the second extruder, a single-screw extruder
(the operating speeds are controlled from a single control panel), where it is cooled to a specified temperature. To implement this task, each part of the extruder has an oil cooling circuit  and a separate oil station for temperature control (PID), the extruder screw and the connecting segment also have a separate oil station. The principle of operation of the oil station is as follows. The operator sets the required temperature on a single control panel. The oil station turns on the circulation of oil in the circuit with heating /cooling to the specified temperature. The oil station itself has a heating element and is fed into a single cooling system (water circuit with a separate cooling unit). The process of maintaining the temperature is carried out automatically.

After this, the melt mass passes through the connecting element, enters the static mixer, where it is additionally mixed and stabilized. The temperature of the static mixer is set from a single control panel and controlled by a separate oil station

Then the mass enters the die - the molding head. When exiting the die, due to the difference in pressure inside
the die and atmospheric pressure, the mass expands and increases in volume (it is a hot foam made of plastic with small cells). The die temperature is regulated by 2 oil stations (optionally, it is possible to increase the number of stations) from a single control panel at the exit of the die, the foamed mass enters the calibrating and pulling devices.

A conventional calibrating device consists of two horizontally located plates with the ability 
to adjust their height (optionally, it is possible to manufacture a calibrating device of a different type). By opening/clamping the plates, the mass of foamed plastic is given the primary form of a tape with the required thickness. The calibrating device is controlled from the control panel located directly on it. The temperature of the calibrating device is set on a single control panel and is controlled by a separate oil station. Using a pulling device, the insulation tape is pulled out of the calibrating device. The pulling device consists of two rows of active rollers, which clamp the insulation tape. The speed of the rollers is adjusted from the control panel on the device itself.

After that, the insulation tape moves along passive cooling rollers and enters the additional foaming zone
(optional. This device is used to reduce the cost by reducing the density of the finished product), where the insulation cells additionally expand, the insulation tape itself increases in volume.

At the exit from the additional foaming zone, the insulation tape moves along passive rollers (optional additional cooling devices can be used) cooling and enters the finishing zone of the slab and packaging.

The zone of final processing of the insulation and its packaging (optionally, there are several options for the zone
of final processing of the insulation and several options for packaging with different degrees of automation.
Each of the options is selected for a specific technical task) consists of: The second pulling device. The speed is controlled by the line operator from the control panel of the first pulling device. Devices for longitudinal milling of the edge of the insulation. The device consists of clamping mechanisms, pressure rollers and cutters. The edge of the plate is milled in two types: straight cut or L edge (lock).

The cuttings from under the cutters are sucked out through the aspiration system into the waste storage bin
for further processing. The inclusion of cutters is controlled from the control panel of the finishing zone. The longitudinal milling device is additionally equipped with milling cutters for milling the surface and also a device for applying perforation (optionally, there are several types including different options for processing the surface of the insulation).

After milling the longitudinal edge, the insulation tape is cut to a specified length in the device
for cross cutting. The device is a movable platform equipped with a
"flying knife" and a system of clamping mechanisms and sensors. The operation of the device
is controlled from the control panel of the finishing zone.

The cuttings from under the cutters are sucked through the aspiration system into the waste storage bin for further
processing. The activation of the cutters is controlled from the control panel of the finishing zone. After that, the finished insulation panels go to the finished product packaging zone via a system of active rollers.

The finished product packaging area consists of (optionally selected based on the technical specifications with different types of packaging and different degrees of automation): automatic stacker. The device collects individual insulation panels into a pack of a given size and pushes the pack onto a belt of 
active rollers. The active roller system and the stacker are controlled from the control panel finishing area then the finished pack enters the packaging device, where it is packed in a sleeve made of polyethylene film. The finished pack is sealed at the edges. The operation of the device is controlled from the control panel located directly on the device. The finished pack enters the thermal chamber via the active roller system where, under the influence of temperature, the packaging on the pack is compressed to the required size and tightly grips the insulation pack. The operation of the device is controlled from the control panel located directly on the device.

The operator packer loads the finished packs onto the front loader and takes them to the finished goods warehouse.

The area for processing defective products and waste (there are several options with different degrees of automation and different tasks). Consists of: An aspiration system with a bin for storing waste. A crusher for processing defective products. A granulation line consisting of two extruders, a
cooling bath, and a device for cutting granules.

This article shows the basic equipment of the production line. The line configuration is selected individually
in accordance with the Customer's requirements for the physical and technical characteristics
of the finished product, production capacity and other parameters.