Pré-Expanseur par Lots PE-1400 — eps pre-expanders by ChinaEps, CE & ISO 9001 certified.
Le PE-1400 est un pré-expanseur EPS industriel de gamme intermédiaire qui chauffe et expanse les billes de polystyrène en lots contrôlés. Il offre un débit allant jusqu'à 900 kg/h avec une cuve double paroi isolée de 1 400 mm, un recyclage vapeur écoénergétique et une capacité de surveillance à distance. Adapté aux usines EPS moyennes à grandes produisant des panneaux isolants, des emballages et des matériaux de construction en grand volume.
Spécifications Clés
Model
PE-1400 (mid-range batch pre-expander)
Barrel Diameter
1,400 mm
Barrel Construction
Double-layer 304 stainless steel with mineral wool insulation
Batch Capacity
700-900 kg/h (continuous batch cycle)
Certifié CE et ISO 9001 Garantie 5 Ans Réponse Technique sous 24h
Double-layer 304 stainless steel with mineral wool insulation
Batch Capacity
700-900 kg/h (continuous batch cycle)
Target Density Range
8-30 kg/m³ (PLC-controlled batch density)
Density Variance
±0.5 kg/m³ batch-to-batch
Expansion Ratio
40-80× (raw bead to expanded volume)
Steam Pressure
0.18-0.23 MPa (closed-loop regulated)
Steam Consumption
80-100 kg per batch
Cycle Time
4-6 minutes per batch (depending on target density)
Agitator
Bottom-driven 3-blade stainless steel agitator with 30:1 reducer
Weighing System
Electronic ±50g accuracy (5 kg load cell range)
Voltage
380V / 50Hz (220V / 60Hz on request)
Installed Power
30 kW total (agitator 7.5 kW + ancillaries)
Machine Weight
6,000 kg
Dimensions (L×W×H)
2,800 × 2,400 × 4,500 mm
Control System
Siemens S7-1200 PLC + 10.1" Weintek HMI
* Les spécifications sont susceptibles d'être modifiées sans préavis. Contactez-nous pour les données techniques les plus récentes.
Ce que Cette Machine Résout
Trois problèmes de production éliminés par cette machine — avec des solutions ingénieriques et mesurables.
Le Problème
Une densité de mousse irrégulière gaspille 8 à 15 % de matière première par lot
Comment Cette Machine le Résout
Le PE-1400 utilise un système de pesage électronique de haute précision et une détection automatique du niveau de matière, maintenant la variance de densité sous ±0,5 kg/m³ et réduisant le gaspillage de matière première à 1-2 %.
Le Problème
Le contrôle manuel de la vapeur entraîne une expansion irrégulière des billes et des rebuts au moulage de formes
Comment Cette Machine le Résout
La régulation en boucle fermée de la pression vapeur par PLC (0,18-0,23 MPa) maintient le taux d'expansion à ±2 fois sur tous les lots — le taux de rebut au moulage de formes en aval chute de 6-9 % à moins de 2 %.
Le Problème
Un préchauffage long et des cycles lents limitent le débit du Pré-Expanseur
Comment Cette Machine le Résout
Cuve à double paroi isolée et système de recyclage de vapeur réduisent le préchauffage de 40 % et accélèrent le temps de cycle 700-900 kg/h par rapport aux conceptions monocouche plus anciennes.
Inside the Machine — Core Components
Eight engineered subsystems that make this cutting line production-grade. Each component is sourced, built, and tested for industrial duty cycles.
1. Double-Layer Insulated Steel Barrel
Function
The main expansion chamber where raw EPS beads are heated by saturated steam injection. Double-layer construction with mineral-wool insulation cuts heat loss to the factory environment and reduces steam consumption by 30-40% vs single-layer barrels.
Engineering Details
1,400mm diameter, 304 stainless steel inner shell with 50mm mineral wool insulation under stainless outer shell. Working pressure rating 0.4 MPa (2× operating pressure for safety margin). Inspection port at top; conical bottom for clean discharge. Pre-heat time 8-12 minutes from cold start.
2. Closed-Loop Steam Control Manifold
Function
Regulates steam pressure into the barrel within ±0.005 MPa of setpoint. The closed-loop control is what makes density variance ±0.5 kg/m³ — manual valves can't hold this kind of consistency batch-to-batch.
Engineering Details
Pneumatically actuated control valve + redundant safety relief valve + digital pressure transducer. Setpoint 0.18-0.23 MPa adjustable on HMI. Steam recycling loop captures condensate back to boiler — energy savings 25-30% over open-vent designs.
3. Bottom-Driven 3-Blade Agitator
Function
Continuously stirs the expanding beads to prevent clumping, hot spots, and scorching. Bottom-drive design eliminates the seal leakage that plagues top-drive agitators after 6-12 months of service.
Engineering Details
3-blade 316 stainless steel agitator, 30:1 worm-gear reducer with 7.5 kW SEW Eurodrive motor. Variable-frequency speed control 15-45 RPM via VFD. Mechanical seal rated 10,000+ hours; replaceable from below without dismantling barrel.
4. Electronic Weighing Batch Loader
Function
Pre-weighs the exact mass of raw EPS beads for each batch (typically 8-18 kg depending on target density). The weighing accuracy directly determines final density consistency.
Engineering Details
±50g accuracy via 5 kg load cells (German HBK or Mettler-Toledo). Pneumatic gate valve releases pre-weighed batch into barrel. PLC stores recipes per density grade; switching from 12 kg/m³ to 25 kg/m³ takes 30 seconds vs 15 minutes manual.
5. PLC + HMI Control System
Function
Supervises every parameter (steam pressure, temperature, batch mass, agitator speed, cycle timer, discharge sequence) in real time. Density recipe library + production logging enables QC traceability.
Engineering Details
Siemens S7-1200 PLC with 14 DI / 10 DO / 2 AI. Weintek MT8102iE 10.1" HMI with multilingual UI (EN/ZH/ES/PT/FR/RU/AR). USB recipe export for backup; optional Ethernet/IP for MES integration. Local fault log retains 1,000 events.
6. Fluidized Bed Dryer (Optional)
Function
Post-expansion stage that gently dries the freshly expanded beads before they enter the aging silo. Removes surface moisture that would otherwise cause clumping during the 24-72h aging period.
Engineering Details
Vibrating perforated tray with hot-air flow; bead dwell time 5-10 minutes. Drying temperature 35-50°C (gentle enough to prevent shrinkage). Cyclone separator captures fines for recycling. Optional add-on — recommended for cold-chain or fish-box producers.
7. Pneumatic Discharge System
Function
Conveys expanded beads from the barrel to the aging silo (10-30m away). Pneumatic conveying is the industry standard — no mechanical augers or belts to damage the delicate freshly-expanded beads.
Engineering Details
Roots blower-based pneumatic conveyor, Ø150mm stainless steel duct. Conveying rate matched to batch discharge rate. Anti-static design prevents bead accumulation in elbows. Cyclone separator at silo inlet — 99% bead capture, 1% fines returned to scrap recovery.
8. Safety & Emergency Systems
Function
Protects operators and equipment from steam pressure excursions and electrical faults. Critical for unattended operation in modern lights-out factories.
Engineering Details
Pressure relief valve set 0.30 MPa (above max operating). E-stop mushroom on operator panel + machine side. Steam pressure interlock prevents agitator start until barrel sealed. Thermal cutoff trips heating if cabinet > 60°C. CE certified per EN 60204-1 and EN ISO 13849-1 PLd.
Principe de Fonctionnement
Le PE-1400 expanse les billes EPS brutes par injection de vapeur saturée dans la cuve en acier inoxydable de 1 400 mm. Le PLC contrôle la pression vapeur, la durée d'expansion et le poids de décharge ; l'agitateur garantit un chauffage uniforme ; les billes finies sont déchargées automatiquement vers le silo de maturation.
Step 1
1. Alimentation
Billes EPS brutes chargées depuis la trémie via pesage électronique (précision ±50 g).
Step 2
2. Injection de Vapeur
Vapeur saturée (0,18-0,23 MPa) injectée ; agitateur tournant à 30-50 tr/min pour expansion uniforme.
Step 3
3. Expansion
Les billes s'expansent 40-80×, la densité descend à 12-30 kg/m³ selon la formulation.
Step 4
4. Décharge
Décharge automatique vers le silo de maturation lorsque la densité cible est signalée par le capteur de niveau et le densimètre.
Step 5
5. Maturation
Les billes mûrissent 8-24 heures dans le silo à lit fluidisé ; prêtes pour le moulage de formes ou par blocs.
Avantages de Performance Ingénieriques
Chaque avantage soutenu par des spécifications mesurables — pas d'allégations marketing sans données.
Économie d'Énergie
25-35%
vs vs traditional single-layer pre-expanders
L'isolation à double paroi et le recyclage de vapeur réduisent la consommation de vapeur par tonne de billes expansées.
Variance de Densité
±0.5 kg/m³
vs industry typical ±2-3 kg/m³
Le pesage électronique et le PLC en boucle fermée maintiennent chaque lot dans une tolérance serrée — moins de rebuts en aval.
Débit
700-900 kg/h
vs vs PE-1200 at 500-700 kg/h
Augmentation de capacité de 40 % sur la même emprise au sol d'usine.
Temps de Cycle
90-120 s
vs vs older 150-200 s designs
Chauffage plus rapide et décharge automatique réduisent le temps de cycle par lot de 30-40 %.
Applications de Production Réelles
Voyez où cette machine s'intègre dans des usines réelles.
EPS insulation board production for EIFS/ETICS façade systems — uniform-density beads feed downstream block molding
Appliance and electronics packaging — controlled 18-22 kg/m³ density for impact protection
Fish-box and aquaculture foam-box production — paired with SM-1200 shape molding for cold-chain markets
Cold-storage warehouse panel manufacturing — premium 25-30 kg/m³ density consistent across batches
Building material wholesale supply — standard EPS bead grades for distribution-side packagers
Fruit and produce packaging — lightweight 12-15 kg/m³ density for export pallets
Configuration de la Machine
Composants de qualité industrielle de marques mondiales établies — chaque pièce traçable.
Composant
Marque / Spéc.
Détail
Contrôleur PLC
Siemens S7-1200
PLC de qualité industrielle, fiabilité 24/7, prêt pour la télésurveillance.
Écran Tactile HMI
Siemens / Weintek
HMI couleur 10 pouces, menu multilingue, stockage de recettes.
Électrovanne Vapeur
Burkert / SMC
Régulation de pression en boucle fermée, précision ±0,01 MPa.
Système de Pesage
Mettler Toledo
Cellule de charge électronique, précision ±50 g sur la plage 0-50 kg.
Moteur d'Agitateur
Siemens
5,5 kW à variateur VFD, 30-50 tr/min variation continue.
Matériau de la Cuve
SUS304
Acier inoxydable double paroi 304 qualité alimentaire, paroi 5+10 mm.
Études de Cas Clients
Détails clients disponibles sur demande.
RussiaAnnée: 2024
Configuration
2 × PE-1400 + ligne BM-6000, 25 t/jour
Résultat
Remplacement de deux Pré-Expanseurs coréens vieillissants ; le gaspillage de matière première est passé de 12 % à 2,5 % au premier trimestre ; retour sur investissement en 14 mois.
EgyptAnnée: 2025
Configuration
1 × PE-1400 + ligne d'emballage SM-1400
Résultat
Un OEM local d'électroménager a réduit le coût d'emballage de 18 % en passant de la mousse moulée importée à la production interne.
Maintenance & Safety
A clear schedule keeps the line running. Built-in safety systems protect operators and product alike.
Maintenance Schedule
Daily (every shift)
Inspect steam manifold for leaks. Clean weighing hopper of bead residue. Check HMI fault log; clear non-critical alarms. Verify agitator runs smoothly at start-up — no unusual noise or vibration. Confirm pneumatic conveyor airflow.
Weekly
Inspect agitator shaft seal for moisture. Lubricate gear reducer per SEW spec (NLGI-2 grease, 50g). Drain condensate from steam line low points. Check VFD heatsink airflow. Verify load cell calibration with reference weight (5 kg ±0.05 kg target).
Monthly
Open inspection port; clean barrel interior with food-grade detergent. Inspect agitator blades for wear or pitting. Check pneumatic conveyor pipe for bead accumulation in elbows. Service air-prep filter/regulator. Backup PLC recipe library to USB.
Major overhaul: replace agitator mechanical seal (10,000h spec), recalibrate load cells, re-certify safety circuit per EN 60204-1, update PLC firmware if Siemens advisories apply, refresh operator training including density-recipe management.
Safety Features
CE certification per EN 60204-1 (machinery electrical safety) and EN ISO 13849-1 PLd (safety-related control systems)
Pressure relief valve at 0.30 MPa setpoint — vents safely if barrel over-pressurizes
Steam pressure interlock prevents agitator start until barrel is sealed and pressurized
Two emergency-stop mushrooms — operator panel + machine side — Category 0 stop within 100ms
Thermal cutoff in electrical cabinet (>60°C) — auto-shutdown logged for audit
The questions buyers ask most often before placing an order.
How is the PE-1400 different from the older PE-1200 / PE-900 batch pre-expanders?
Three main differences: (1) Bigger barrel (1,400mm vs 1,200mm) = higher batch capacity per cycle = lower cost per kg of expanded bead; (2) Closed-loop PLC steam regulation (vs older PE-1200 manual valves) = density variance ±0.5 kg/m³ vs 2-4 kg/m³; (3) Double-layer insulated barrel + steam recycling = 30-40% lower steam consumption vs single-layer designs. Net: PE-1400 is the sweet spot for medium-large factories (5,000-30,000 m² monthly output).
What density range can the PE-1400 achieve, and how accurate is it?
Target density range 8-30 kg/m³. Variance ±0.5 kg/m³ batch-to-batch on the same recipe. Lower densities (8-12 kg/m³) require slightly longer cycle times (5-6 min) for full expansion; higher densities (25-30 kg/m³) cycle faster (3-4 min). For super-low density (<8 kg/m³) or high-density (>30 kg/m³ FR-grade), consider PE-1800 instead.
Can the PE-1400 handle flame-retardant graphite EPS?
Yes for standard FR grades up to 30 kg/m³. The steam manifold + closed-loop control hold the precise temperature window FR additives need to activate without scorching. For higher-density FR (30-45 kg/m³) used in premium high-rise construction, PE-1800 is recommended due to its higher steam capacity.
What is the steam boiler requirement to operate the PE-1400?
Minimum 0.5-ton/h steam boiler at 0.4 MPa working pressure. Most customers run a 1-ton/h boiler to cover the PE-1400 + downstream block molding (BM-1400) + shape molding (SM-1200) lines. ChinaEps can quote the matching boiler if needed.
How long is the wear life on the agitator mechanical seal?
Rated 10,000+ hours of operation (typically 2-3 years of single-shift use). Replacement is a 2-hour job — accessible from below without dismantling the barrel. Spare seal kit ships with every machine. We use Burgmann or John Crane seals (European spec).
Does the PE-1400 ship to 220V/60Hz countries?
Yes — factory build option. We swap the agitator motor (SEW Eurodrive 220V/60Hz variant), VFD, and contactors. PLC and HMI are voltage-flexible. No price difference; 2-3 week lead time adjustment.
What is the cycle time, and how many batches per hour?
Cycle time 4-6 minutes per batch depending on target density. At 5-minute average cycles, the PE-1400 runs 12 batches/hour = ~108 kg of finished beads/hour at 9 kg/batch = 700-900 kg/h finished throughput depending on density. Two-shift operation reaches 14+ tons/day.
Can the PE-1400 integrate with my existing aging silos and block molding line?
Yes — the pneumatic discharge system has standard Ø150mm flanges that connect to any cyclone-equipped aging silo. The PLC has analog and digital I/O for upstream/downstream handshaking (start interlock with boiler, discharge ready signal to silo). Most retrofits complete in 1-2 days on site.
What is the operator training requirement?
Two options: (1) factory training at Qingdao for 2-3 days during pre-shipment testing (you cover travel); (2) on-site training at your facility for 3-5 days commissioning + training (you cover travel + accommodation). Training covers PLC recipe management, density tuning, troubleshooting, maintenance schedule. Materials in EN / ZH / ES / PT / FR / RU / AR.
How is the PE-1400 packed and shipped?
One 40HQ container fits the PE-1400 + electrical cabinet + spare parts kit. Barrel is shipped fully assembled (no risk of seal misalignment during reassembly). All steel surfaces oil-coated and shrink-wrapped against salt-air corrosion. Sensitive electronics in foam-lined wooden crates. Total weight ~6,500 kg.
Build a Complete EPS Line
This machine integrates into the full ChinaEps production flow — upstream, downstream, and auxiliary equipment from one supplier.
