Pré-Expanseur Automatique EPS par Lots - fabricant de machines EPS Chine

PE-1400

CE ISO 9001

Pré-Expanseur Automatique EPS par Lots

Name: Pré-Expanseur Automatique EPS par Lots
Brand: ChinaEps
Availability: PreOrder

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Pré-Expanseur Automatique EPS par Lots — eps pre-expanders by ChinaEps, CE & ISO 9001 certified.

Nous fabriquons le pré-expandeur EPS par lots PE-1400 — 700-900 kg/h, précision ±0,5 kg/m³, intégration SCADA. Certifié CE, 60+ pays.

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 Structurelle 5 Ans Réponse Technique sous 24h

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Inside the Machine — Core Components

Eight engineered subsystems that make this machine production-grade. Each component is sourced, built, and tested for industrial duty cycles.

1. Pre-Expander Vessel (304SS Double-Layer Pressure Vessel)

Function

The main pressure vessel where raw EPS beads are batch-heated with steam to expand into low-density pre-expanded beads. Yellow safety platform for top-access maintenance + monitoring.

Engineering Details

Double-layer 304 stainless steel construction (60mm mineral wool insulation on PE-1800). Barrel diameter 1.2-1.8 m. TUV / Bureau Veritas pressure-vessel certified. Working pressure 0.15-0.25 MPa with safety relief valve at 0.4 MPa. Cleanable interior with engineered drainage.

2. Agitator Drive Unit (Bottom-Driven Industrial Reducer)

Function

Mechanical drive system that rotates the bottom-mounted agitator blades — keeps beads in continuous gentle motion during steam expansion to prevent clumping and ensure uniform density. The most stress-loaded component of the pre-expander.

Engineering Details

SEW-Germany or NORD-Germany helical-bevel gear reducer (30:1 ratio). 7.5-11 kW agitator motor (3-blade 304SS standard / 4-blade 316SS dual-bearing on PE-1800 — handles FR-graphite EPS without bearing wear). VFD speed control on premium PLC models.

3. Drying & Cooling Unit (Fluidized Bed + Bead Aging Silo)

Function

Removes residual moisture and stabilizes pre-expanded beads. Fluidized bed circulates warm air evenly across beads, then transfers to aging silo for 6-24 hour pentane gas release — critical for downstream block-molding fusion quality.

Engineering Details

Antistatic synthetic-fabric storage silo (1.5-150 m³ capacity range). Foam Induction Density Controller — automatic sampling + fixed-volume weighing + real-time PLC feedback adjusts density without manual intervention (Fackel-class precision). Bead transfer via smooth-interior pipes (Kurtz cellular-wheel sluice optional).

4. Air Blower (High-Pressure Industrial Centrifugal)

Function

High-pressure blower delivers air for fluidizing the drying bed and pneumatically conveying expanded beads from pre-expander to aging silo. Insulated cabin reduces noise and heat loss.

Engineering Details

5.5-7.5 kW industrial centrifugal blower with built-in air-cooled heat exchanger (yellow safety frame mounted). Anti-static internal coating prevents bead clumping. Optional rotary cellular-wheel feeder for metered bead transport. Air pressure 0.05-0.08 MPa typical operating.

5. Bottom Discharge Valve (Pneumatic-Gear Hybrid)

Function

Releases expanded beads from pre-expander vessel into the pneumatic conveying system after each batch. Pneumatic-gear hybrid mechanism ensures smooth release without bead damage.

Engineering Details

Festo-Germany pneumatic actuator (rated 1 million+ cycles) + worm-gear backup for power-loss safety. Ø 200-280 mm discharge opening sized by model. Anti-static valve seat prevents bead static buildup. Sealed against steam leakage during heating cycle.

Spécifications Techniques

4 models

Paramètre	PE-1200 (Entry / Small batch)	PE-1400 (Mid-range / Most popular)	PE-1600 (Expansion-stage)	PE-1800 (Premium / Flagship)
Tier	Entry-level — small EPS factories	Mid-range workhorse — 80% of customers choose this	Mid-large — factories scaling up production	Premium flagship — FR-graphite + ATEX + SCADA + EU export
Barrel Diameter	1,200 mm	1,400 mm	1,600 mm	1,800 mm
Barrel Construction	304 stainless steel + insulation	Double-layer 304 stainless + mineral wool insulation	304 stainless + insulation	Double-layer 304 stainless + 60mm mineral wool + steel outer shell
Capacity	500-700 kg/h	700-900 kg/h	1,000-1,300 kg/h	1,400-1,700 kg/h
Expansion Ratio	40-80× (raw bead to expanded)	40-80×	40-80×	40-80× (handles FR-graphite EPS to 8 kg/m³)
Density Range	12-40 kg/m³	8-30 kg/m³	8-35 kg/m³	8-45 kg/m³ (includes flame-retardant grades)
Density Variance	±1.0 kg/m³ (manual sampling)	±0.5 kg/m³ (PLC-controlled batch)	±0.5 kg/m³	±0.3 kg/m³ (premium precision, 2× better than PE-1400)
Steam Pressure	0.15-0.22 MPa	0.18-0.23 MPa (closed-loop regulated)	0.20-0.25 MPa	0.20-0.25 MPa (multi-zone closed-loop)
Steam Consumption	65-80 kg / batch	80-100 kg / batch	100-120 kg / batch	120-140 kg / batch
Steam Manifold Ports	4 ports	4 ports	6 ports	8 ports (vs 4 on PE-1400 — uniform for large barrel)
Agitator	Bottom-driven 3-blade 304 stainless	Bottom-driven 3-blade 304SS + 30:1 reducer, 7.5 kW	Bottom-driven 4-blade 304SS, 9 kW	4-blade 316 stainless, dual-bearing bottom-driven, 11 kW
Cycle Time	5-7 min / batch	4-6 min / batch	3.5-5 min / batch	3-5 min / batch (faster than PE-1400)
Installed Power	22 kW	30 kW	37 kW	45 kW
Machine Weight	4,500 kg	6,000 kg	8,000 kg	10,000 kg
Control System	Siemens S7-1200 + 7" HMI	Siemens S7-1200 + 10.1" Weintek HMI	Siemens S7-1200 + 10.1" Weintek HMI	Siemens S7-1500 + 12.1" Weintek HMI + SCADA
Certifications	CE	CE + ISO 9001	CE + ISO 9001	CE + ISO 9001 + ISO 14001 + ATEX (FR-graphite zones)

* 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 1

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 2

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 3

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.

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.

Auto Density Controller

±0.3 kg/m³ on PE-1800

vs Manual-sampling competitors: ±1.5-2.0 kg/m³

Foam Induction Density Controller: automatic sampling + fixed-volume weighing + real-time PLC adjustment. No manual operator sampling needed. 4-6× tighter precision than manual-sampling competitors (Fackel-class engineering).

Multi-Port Steam Manifold

4 → 8 ports (model-dependent)

vs Generic competitors: 2-4 ports only

PE-1200/1400 use 4 ports, PE-1600 uses 6, PE-1800 uses 8 ports — larger barrel (1.8 m) requires more steam injection points to prevent "center cold spot" defect. Gemu / Burkert German proportional valves on each port.

ATEX Explosion-Proof (PE-1800)

Zone 22 dust-ignition rated

vs Standard competitors: no ATEX option

FR-graphite EPS processing generates fine carbon dust — has explosion risk in heating zones. PE-1800 ATEX option includes intrinsically-safe sensors + explosion-proof motor housings + bonded grounding — required by EU/Middle East regulations for graphite EPS lines.

Pre-Loading Silo Integration

0.15-3.0 m³ feed silo + PLC weighing

vs Manual hopper competitors: 30 min batch setup

Pre-loading silo with electronic weighing + PLC-calculated parameters + vacuum-assisted transfer eliminates manual hopper filling between batches. Operator sets density target and walks away — batch setup time drops from 30 min to 2 min (Eprotech-class throughput).

Triple Safety + TUV-BV Certified

Pressure vessel + ATEX + interlocks

vs Industry typical: 1-2 safety layers

Computer supervision + foam pressure feedback + hardware safety relief valve at 0.4 MPa. TUV / Bureau Veritas pressure-vessel certificate for EU export. ATEX certification (PE-1800) for graphite-zone deployment. EN 16163 compliance test report available.

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.

Russia Année: 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.

Egypt Année: 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.

Semi-Annual

Recalibrate steam pressure transducer (±0.005 MPa accuracy spec). Replace pneumatic conveyor cyclone separator filter. Verify safety relief valve operation at 0.30 MPa setpoint. Inspect electrical cabinet terminals; torque to 4 Nm.

Annual

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
Anti-static pneumatic conveyor duct prevents EPS dust ignition risk per ATEX zone-22 guidelines
Inspection port interlock prevents barrel opening while pressurized
Density-recipe change requires supervisor-level HMI login — prevents accidental parameter change mid-shift

Live Footage

See This Machine Running

Real ChinaEps production line footage from customer factories — not stock video.

EPS Pre-Expander Machine — 2023 Customer Line Actual Shooting

EPS Pre-Expander Machine in Operation

Browse all 20+ videos on YouTube

Build a Complete EPS / EPP Line

This machine integrates into the full ChinaEps production flow — upstream, downstream, and auxiliary equipment from one supplier.

Upstream — Bead Preparation

Raw EPS Beads Supply

Standard, fast-cycling, flame-retardant, or graphite-grade EPS beads. ChinaEps supplies in 25kg bags or 1000kg jumbo bags via partner producers across China.

Steam Boiler (0.5-1 ton/h)

Matched gas-fired or biomass steam boiler at 0.4 MPa working pressure. Quoted on request with the matching softener and feedwater system.

Downstream — Finishing & Packing

EPS Aging Silos

Fluidized-bed aging silos hold freshly expanded beads 8-72h for moisture and pressure stabilization. Required between PE-1400 and any block-molding or shape-molding station.

BM-1400 Block Molding Machine

Forms aged beads into 6,000mm-long EPS blocks ready for the SPQ-B cutting line. Steam-chest fusion produces uniform-density blocks.

SM-1200 Shape Molding Machine

Forms aged beads into final molded shapes (fish boxes, cooler boxes, appliance inserts). Direct alternative to BM-1400 for shape-molded products.

Auxiliary Systems

Pneumatic Conveying Network

Connects PE-1400 outlet to multiple aging silos. Modular pipe sections + diverter valves for flexible layout.

Density Testing Lab Equipment

Bench-top density meters + balance scales for in-house QC of finished bead density. Recommended for premium FR or export-grade producers.

Aperçu ROI

Chiffres de référence rapides — pour un devis précis avec vos données d'usine, utilisez le Calculateur ROI.

Investissement Équipement

~$1,400-1,600/ton FOB illustrative (quote-specific)

Période de Retour sur Investissement (ROI)

12-15 mois en fonctionnement continu à 700-900 kg/h

Débit

Jusqu'à 7,2 tonnes/jour en simple poste, 14+ tonnes/jour en double poste

Lancer le Calculateur ROI Détaillé →

Product FAQ

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.

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