PVC FLOOR TILE EXTRUSION MACHINERY1. Brief
The new type of PVC floor is widely used in housing renovation and decoration project. Compared with traditional floor tiles, it has many advantages, such as green and environment-friendly feature, light and thin, much cheaper price, good performance in abrasion resistance, etc.
Generally there are two ways to produce multiple compound type pvc floor tile. The first method is banbury machine and thermo-press which can produce floor tiles with high capacity, the second way is extrusion machine and laminating machine whose cost is much less than first one, and suitable for the manufacture who don't have enough experience in PVC floor tile production. And this project is mainly talk about the extruder and laminating machine to produce PVC floor tiles.
2. Production and machinery
1) Process
First compound the material according to the formula, then the compounded material will be transported to the extruder, after the extruder, there is a T dies mould which is pretty important and will decide the shape of the pvc floor. After T-dies there is a three rollers calendaring machine and it can laminate the printing layer, wearing layer and base layer. The whole process is simple.
2) Raw material and formula
| No. |
Items |
units/Kg |
Remark |
| 1 |
PVC |
100 |
|
| 2 |
CaCO3 |
300 |
300 mesh |
| 3 |
Edge material/Recycle |
50 |
|
| 4 |
Ca-Zn Stabilizer |
5 |
|
| 5 |
PVC lubricant ZB-60 or ZB-74 |
0.8 |
|
| 6 |
PE wax |
0.6 |
|
| 7 |
CPE anti-impact modify agent(135-A) |
5 |
|
| 8 |
ACR modify agent ACR ZB-20 ZB-1 |
3 |
|
| 9 |
PVC lubricant agent ZB-175 ZB-101 |
1 |
|
| 10 |
Carbon black |
0.5 |
Pigment |
3) Utility and cost
Power:75KW
Labors:6~7 skilled workers every line
Compressed air:5kw
Water recycle system:5m*5m*2m water pool changed every three month
Price:(4mm base layer, printing layer, wearing layer 0.7mm)
Cost:
Base layer:19.91 yuan/m2
Printing layer and wearing layer:1.1 yuan/m2
Others:2.1yuan/m2
Total cost :22.6 yuan/m2
Capacity:21.6ton/2700m2 per day (24 hours)
Compared with banbury + thermo-press machine:
Method
Items |
Banbury machine + thermos-press machine |
Extruder + laminating machine |
| Capacity |
80~100ton/day(10000~12000m2) |
21.6ton/day(2700m2) |
| Price |
Around $ 1500,000~$2500,000 |
Around $ 170,000 |
| Manpower |
More than 20 workers because of four process |
6~7 skilled worker |
4) Machineries
1. PS115/28 Twin screw extruder
| No. |
Items |
Model |
Number |
Manufacture |
| 1 |
Screw |
Φ115 |
1 pair |
Ruichang |
| 2 |
Tank |
Φ115 |
1 piece |
Ruichang |
| 3 |
Transmission system |
PSJ115/22B -02-00 |
1 set |
Ruichang |
| 4 |
Cooling system |
|
1 set |
Zhejiang |
| 5 |
Vacuum exhaust system |
|
1 set |
Ruichang |
| 6 |
Vacuum pump |
SZ-2,4KW |
1piece |
Ruichang |
| 7 |
Transmission box lubrication cooling system |
PSJ115 -03-00 |
1set |
Ruichang |
| 8 |
AC inverter motor |
Y4-280-31-75kW |
1 set |
Siemens |
| 9 |
Twin screw feeding device |
1.5kW |
1 set |
Shanghai |
| 10 |
Main motor AC inverter |
510- 75kw |
1 piece |
ETD |
| 11 |
Feeding motor inverter |
510- 1.5kw |
1 piece |
ETD |
| 12 |
Distribution box bearing |
SL18 5015 |
8pieces |
INA |
| 13 |
Combined bearing |
HS915 |
1 piece |
Customized |
| 14 |
Thrust spherical roller bearings |
9039424E |
1 piece |
Dalian |
| 15 |
Melt pressure sensor |
PT131 |
1 piece |
Chengdu |
| 16 |
AC contactor |
3TB |
1 set |
Schneider |
| 17 |
Solenoid valve |
DF-15 |
3 pairs |
Shanghai |
| 18 |
Mini breaker |
L7series |
|
Schneider |
| 19 |
Axial fan |
0.55KW |
6pieces |
Shanghai |
| 20 |
Button |
|
1 set |
Schneider |
| 21 |
Potentiometer |
3590S |
3pieces |
Schneider |
| 22 |
Alarm |
|
1piece |
Schneider |
| 23 |
Aviation sockets |
|
8pieces |
Shanghai |
| 24 |
Thermostat in screw |
|
1 set |
Zhejiang |
| 25 |
Thermometer |
RKC400 |
12piece |
Japan |
2. T-dies mould
| Material |
5CrNiMo |
| Mold surface |
Polished and levelling |
| Dimension |
Width:1350mm |
| Adjustment range |
1-4.5mm |
| Heating area |
Temperature control 10 points |
| Accessories |
A support vehicle needed to bear the mould |
3. Three roller calendaring machine
| Type |
Three-roll vertical type |
| Roller |
Diameter:φ400mm, length:1500mm.Good quality seamless stain, surface hardening treatment. Surface hardnessHRC50-55. |
| Frame |
Steel plate welding and tempering treatment |
| Bearing seat |
Forging material |
| Drive unit |
Separate gearbox driven |
| Power unit |
AC motor 2.2KW |
| Control unit |
Using ABB or ETD brand inverter control. Three rollers and tractor can be adjusted individually or simultaneously. |
| Roller spacing controller |
Electric mechanical transmission |
| Roller movement |
Linear guide |
| Bearing |
High temperature bearings |
| Rotary joint |
Using 6 pieces 1.25 "swivel joints. |
| Safety facilities |
Limit switch and emergency stop switch. |
4.Hot laminating device: 1 set
Laying the printing layer and wearing layer.
5.Roller temperature controller:1 set
| Cooling medium |
Oil |
| Temperature range |
50-180ºC |
| Type |
Three roller Integrated |
| Temperature control accuracy |
≤±1ºC, with automatic pressure, temperature, pump alert. |
| Pump power |
2.2 KW, three set |
| Heating tube |
18kw/group, three groups, corrosion resistance. |
6.Cooling conveyor:1 set
| Length |
8meters, two sections, square tube structure |
| Driven unit |
No need |
7.Cutting device:1 set
To cut the material into regular dimension.
8. Traction machine
| Rubber roller |
Diameter:φ250mm, length:1500mm. |
| Clamping method |
One pair of roller, pneumatic clamping |
| Drive motor |
AC motor 2.2KW |
| Reducer |
Independent reducer |
| Control unit |
The control unit is controlled by ABB or ETD brand inverter. The tractor and the three rollers can be adjusted individually or simultaneously |
| Electric box |
Independent, made by medium carbon steel |
| Safety facilities |
Using German-made safety line device |
9.Length meter: 1 set
Taiwan or Japanese brand, automatic counting length.
10.Shears:1 set
| Size |
Can be customized, maximum width is 1500mm |
| Power unit |
5.5KW AC brake motor |
| Lifting unit |
Cam structure |
| Control unit |
Control the length meter, manual and automatic two modes |
| Electric box |
Independent, made by medium carbon steel. |
11.Sucker type moving station: 1 set
| Method |
Oil-free vacuum pump, power:600W |
| Number of suckers |
6 pieces |
| Vertical movement distance |
1m, a gear motor(0.75KW) drive the station |
| horizontal movement distance |
3m, a gear motor(0.75KW) drive the station |
| Movement speed |
10m/min |
| Dimension |
Length:4650mm, Height:3500mm |
12.Electrical control system: 1 set
| Electric control box |
Integral |
| Operating box |
Cantilevered, mounted on a three-roll machine. |
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