PVC-free Foaming Extrusion Line

The PVC-free foaming extrusion line is a technologically advanced professional production system specifically designed for manufacturing high-quality, lightweight, and eco-friendly PVC-free foaming boards( commonly known as “Foam PVC Board” or “Andy Board”). This production line discards common lead-containing PVC formulas, adopting an environmentally friendly calcium-zinc stabilizer program. It integrates the sophisticated “Celuka” or free frothing process to accomplish controlled foaming within a closed mold. The produced boards feature a great body level, a dense core, outstanding surface softness, and an excellent strength-to-weight ratio. Its important advantages lie in the properly secure foaming system, effective two-stage extruder settings, and brilliant temperature management, making it an ideal choice for producing high-quality bubbled products such as advertising display boards, architectural decoration materials, furniture cabinets, and gentle partitions.

This production line is specially designed for the tough technique of PVC foaming materials, focusing on solving four primary challenges: foaming portion control, surface quality, density uniformity, and dimensional stability.

Core Technical Rewards

Two-Stage Extrusion and Precision Foaming System

Two-Stage Extrusion Configuration( Core Design): First-Stage Main Extruder: Responsible for the efficient plasticization, mixing, and preliminary homogenization of the material. It features a high-strength, high-torque design to ensure the best melting and constant temperature of the materials before the frothing agent is added.

Second-Stage Metering Extruder: Acts as the “heart “of the plan, connecting the powerful mixer and the foaming shoot. Its main function is to create a stable, high-pressure evaporative flow and to command the melt temperature at the important point of foaming agent decomposition. This ensures consistent and controlled growth, the quick evaporate exits the live lip and enters the low-pressure zone.

Precision Foaming Control System

Dedicated Foaming Screw and Die: The switch type amounts to expressing, cutting, and mixing to prevent unwanted degradation of the foaming agent. The kill employs a certain movement flow design with precisely controlled heating and cooling zones to create an appropriate frothing environment.

Static Mixer: Ensures molecular-level blending of the foaming agent, additives, and the dissolved, providing the actual basis for achieving a consistent mobile structure.

High-Precision Temperature Control System: The entire collection utilizes Pi smart temperature control across 20-30 zones. Particularly for the second-stage extrusion, a powerful mixer and shoot, temperature control accuracy reaches ±0.5°C, which is key to stabilizing the frothing percentage.

Sizing and Cooling System

Sizing Casting and Chilling Bed: After exiting the kill, the boiled table immediately enters a measurement mold with specific inside cavity dimensions for primary cooling and shaping. It then proceeds to a multi-section flexible heat sleep for slow, common more cooling via water or air chilling, preventing table deformation, inside stress, or core shrinkage caused by overly rapid cooling.

Haul-Off and Cutting System

High-Powered Multi-Roll Haul-Off Unit: Provides reliable and efficient pulling force to overcome opposition between the boiled board and the sizing mold.

Precision Saw: Equipped with carbide-tipped blades to achieve a fresh, chip-free cut to preset length with a high-gloss end.

Turn-Over Stacker: Automatically flips and stacks the divide boards, protecting the roof system and improving demonstration efficiency.

Intelligent Central Control System

Integrates control over all process parameters (temperature, pressure, speed, vacuum, cooling) and monitors key data in real-time.

Features a “Recipe Management” function for one-touch switching of production parameters for products of different thicknesses and densities.

Significant Configurations and Optional Features

  • Basic Configuration: First-stage major extrusion, second-stage calibration extrusion, electrical panel changer, active blender, dedicated foaming live, measurement mold, cooling bed, haul-off unit, cutting saw, turn-over stacker, and totally automated control system.
  • Advanced Optional Features: Online thickness/density gauge, automatic mixing and batching system, surface laminating machine, online sanding/polishing unit, edge trim shredding and recycling system, MES( Manufacturing Execution System) interface.

Manufacturing Range

Applicable Raw Materials: PVC resin powder( e. g., SG-5, SG-7), eco-friendly calcium-zinc stabilizers, AC foaming agent, and other functional additives.

Completed Product Specifications

Board Density: 0.45- 0.85 g/cm³ (adjustable)

Board Thickness: 3mm- 30mm( mainstream range, thicker sizes customizable)

Board Width: 1220mm, 1560mm( standard), maximum can exceed 2000mm

Manufacturing Capacity: Depending on collection speed and specifications, output is roughly 200- 800 kg/h.

Item Application Range

The PVC-free frothing boards produced by this collection are widely used due to their lightweight character, simple processability, waterproof and moisture-resistant qualities, and smooth appearance:

  • Advertising and Exhibition Display: Screen publishing boards, online UV publishing substrates, exhibition stands and boards, banners.
  • Architecture and Interior Decoration: Indoor/outdoor ceiling cladding panels, roof panels, restroom partitions, door/window shells, skirting boards.
  • Furniture and Cabinet Manufacturing: Cabinet gates, bathroom cabinet body, equipment panels, display cabinet backs.
  • Transportation: Interior sections and separation boards for trucks, trains, and ships.
  • Another Industrial Uses: Structure formwork, cleanroom panels, model-making substrates.