105mm, POLYETHYLENE FOAM SHEET MAKING EXTR...

Process description  1 Hopper & loader Weighing raw materials of LDPE, Talc M/B, Color pigment and etc by required formulation.  And feeding into extruder.   2 Main control panel Heating 4 zones, cooling 3 zones and dies 1 zone.  Total 8 control zones. It controls connected gas pump, M-1, and hopper loader.   3 AC motor control panel It controls  AC motor which is easier to control the speed and good for energy saving than other kinds of motor.   4 Main extruder Raw materials will be input into main extruder through hopper and will be mixed inside. At first point of main extruder, all materials will be mixed and melted. At second point, materials will be foamed by gas.   5 Gas injection pump Gas will be injected into middle point of main extruder for using as foaming gas. The pump inject liquified butane gas into cylinder after changes into high pressured in 80~200kgf/cm2.   6 Dies head & sub-dies Foamed materials will be coming out of main extruder through dies set to be foamed hose product. Approximately 30% gas in hose product cell will be replaced into air. Sub-dies will control required size and shape. Easy to change dies depending on hose size. Dies are made by special heat treatment on surface to protect.   7 Hose air cooling Fan blower will make cooling air for foamed hose product. Cooling air make foamed product fine cell structure and minimize product shrinkage.   8 Water cooling Second cooling by water spray for foamed hose product. Enough cooling for hose product to remove all heat.   9 Hose cutting unit Semi-auto cutting unit to cut the foamed hose product by required size. Easy control to change the required length.   10 Conveyor part Guiding conveyor after cutting.   11 Aging In order to eliminate the gas contained in the cell structure, foamed product will be put in proper temperature for a few days depending on weather temperature.   12 Recycling Scrap of foamed hose product and rejected products should be collected into recycling machine and will be re-produced into pelletized PE resin. These re-produced resin feed back into first stage of raw materials to re-use.   13 Talc Master Batch (Nuclear Active agent) Pelletized type mixing resin, Talc powder, whitening agent and others. If put more, foamed product got small cell structure, dense and smooth surface. If excess of Talc, too many change and product size will be changed. If shortage of Talc, too big cell structure and low quality.   14 M-1 (Surface Active agent) Lubrication inside cylinder and reduce the pressure. Non-shrinkage for product.   15 Butane gas foaming agent for product and cooling too. Too many gas, too bigger cell structure and low quality product. Shortage gas input, good product but too heavy product.