Why is the production speed of a 400mm stone-plastic wall panel production line higher than that of a micro-foamed hollow wall panel production line?

With the competitive global environment of the modern wall panel production we understand that speed in production is a major factor to determine levels of efficiency, cost, and market response. Industry professionals usually inquire: Why does a line of 400mm stone-plastic composite (SPC) wall panel running run faster than a substrate micro-foamed hollow wall panel running?

We have learnt that the solution is not in the ability possessed by the machinery but in the basic differences between the material science and the extrusion processes involved. In Jiangsu Xinhe Intelligent Equipment Co., Ltd. we construct special lines on the two types of products and our experience-level reveals the fundamental technical causes of this speed difference.

Process Comparison: The Core of the Speed Gap

The Stone-Plastic (SPC) Process: A Model for High-Speed Stability

The material that we make is a 400mm SPC wall panel that is produced through dense and processed compound usually a high ratio of calcium carbonate (stone powder), polyvinyl chloride (PVC) with very little foaming agents. Characteristics of this process are the following:

Rapid Heat Transfer & Cooling: We also have an advantage of the high thermal conductivity of the SPC compound. After extrusion through Xinhe precision flat-die the material can be seen to release heat at a rapid pace. Our high-efficiency, multi-stage, high-efficiency calibration and cooling have the ability to solidify the high profile blend in a very short period providing us with the ability to run at higher haul-off speeds commonly greater than 1520 meters an hour at the typical thicknesses.

Stable Dimensional Control: We take advantage of the non-foaming, low-shrinkage property of SPC to start additional sizing in the calibrator in a stable way. We have no need to deal with stagnant growth or complicated cell mechanisms thus making it easier to control the processes and maximize velocity.

Simple Material Rheology: This is where we have a dense SPC melt flow that is extremely predictable and stable at high pressure and throughput. This will enable our twin-screw extruders to run with high rates with uniform output and no surge or wear.

Simply put, we regard the SPC process as the quick cooling and shaping of a viscous paste that is dense and this is a speed conducive undertaking.

The Micro-Foamed Hollow Panel Process: Precision Over Pure Velocity

Our hollow wall panels in micro-foamed structure are designed to have an excellent thermal insulation and better strength-weight ratio. The secret of this performance we gain by an intricate internal organization which determines another rhythm of production:

Critical Foaming & Cell Control: We have to add a chemical foaming agent (CFA) to the melt and activate it. It is indeed a process of quite critical time limitation to form a uniform closed cell microstructure.

Complicated Die and Vacuum Calibration: We are developing the dies for Xinhe that will create hollow foamed panels. The dies will ensure an accurate shape of numerous internal webs and chambers while controlling the internal and external growth of the material.

Slower, Controlled Cooling: We know that the insulating properties of the foam are adversarial of rapid cooling. We are familiar with the fact that the gaseous cells that are trapped reduce the rate of heat exchange between the core and the surface.

We frequently refer to this process as baking a delicate souffle-accuracy, control of swell, sensitivity of setting are of utmost importance and it of course follows that this is a slow process compared with stamping of solid panel casts.

Xinhe's Role: Optimizing Each Process for Peak Performance

In the case of high-speed SPC lines, we pay significant attention to high-torque extruders of dense compounds, efficient cooling banks and a solid haul-off, in order to take advantage of the speed benefits inherent in the process.

In case of micro-foamed hollow panel lines we show our master touch of being able to control the desired temperature, to design screws that ensure flawless foaming a new technology of die and a strictly-controlled cooling areas to be advanced with the quality of the product.

Conclusion: Different Goals, Different Speeds

We find that increased rate of production of 400mm SPC line is directly associated with the increased simplicity and increased density of the material it needs that is optimised to solidify within a short period. Another investment we actually know is the fact that the comparatively reduced speed of a micro-foamed hollow panel line is essential as a means of attaining its high function characteristics of light weight strength and thermal insulation.

In our opinion, it is not about finding the best line that can go through all products regardless of the material type and the item type, but ensuring that the line selected by the manufacturers will work the best on the specific product they are targeting. The advantage of Xinhe is that it offers the tag line: high velocity SPC line to produce in volume and precision foamed-panel line to develop value-added applications to fit the requirement of our clients with the appropriate tool to their market-strategy.

The selection of the production technology is important. Contact the engineering team of Contact Jiangsu today and get an analysis of your product objectives and allow us to present to you a unique solution to meet the best application of speed, quality and profitability that suits your needs.