Pre-Expander Otomatis EPS Batch - EPS machinery manufacturer China

PE-1400

CE ISO 9001

Pre-Expander Otomatis EPS Batch

Name: Pre-Expander Otomatis EPS Batch
Brand: ChinaEps
Availability: PreOrder

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Pre-Expander Otomatis EPS Batch — eps pre-expanders by ChinaEps, CE & ISO 9001 certified.

Kami memproduksi pre-expander EPS batch PE-1400 — throughput 700-900 kg/jam, presisi densitas ±0,5 kg/m³, integrasi SCADA. Bersertifikat CE, 60+ negara.

Key Specifications

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)

CE and ISO 9001 Certified 5-Yr Structural Warranty 24h Technical Response

Kirim Permintaan Download Specifications

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.

Technical Specifications

4 models

Parameter	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)

* Specifications are subject to change without notice. Contact us for the latest technical data.

What This Machine Solves

Three production problems eliminated by this machine — with engineered, measurable solutions.

The Problem 1

Inconsistent foam density wastes 8-15% of raw material per batch

How This Machine Solves It

PE-1400 uses a high-precision electronic weighing system + automatic material level detection to hold density variance under ±0.5 kg/m³, cutting raw material waste to 1-2%.

The Problem 2

Manual steam control causes uneven bead expansion and shape molding rejects

How This Machine Solves It

Closed-loop PLC steam pressure regulation (0.18-0.23 MPa) holds expansion ratio within ±2 times across all batches — downstream shape molding reject rate drops from 6-9% to under 2%.

The Problem 3

Long warm-up + slow batch cycles limit pre-expander throughput

How This Machine Solves It

Double-layer insulated barrel + steam recycling system shortens warm-up by 40% and trims the 700-900 kg/h cycle time vs older single-layer designs.

Working Principle

PE-1400 expands raw EPS beads by injecting saturated steam into the 1,400 mm stainless-steel barrel. The PLC controls steam pressure, expansion time, and discharge weight; the agitator ensures uniform heating; finished beads are discharged automatically to the aging silo.

Step 1

1. Feed

Raw EPS beads loaded from feed hopper via electronic weighing (±50g accuracy).

Step 2

2. Inject Steam

Saturated steam (0.18-0.23 MPa) injected; agitator turns at 30-50 rpm for uniform expansion.

Step 3

3. Expand

Beads expand 40-80×, density falls to 12-30 kg/m³ depending on recipe.

Step 4

4. Discharge

Auto-discharge to aging silo when target density signaled by level sensor + density meter.

Step 5

5. Aging

Beads age 8-24 hours in fluidized-bed silo; ready for shape/block molding.

Engineered Performance Advantages

Every advantage backed by measurable specs — no marketing claims without data.

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.

Energy Saving

25-35%

vs vs traditional single-layer pre-expanders

Double-layer insulation + steam recycling cuts steam consumption per ton of expanded bead.

Density Variance

±0.5 kg/m³

vs industry typical ±2-3 kg/m³

Electronic weighing + closed-loop PLC keeps every batch within tight tolerance — fewer downstream rejects.

Throughput

700-900 kg/h

vs vs PE-1200 at 500-700 kg/h

40% capacity uplift in same factory footprint.

Cycle Time

90-120 s

vs vs older 150-200 s designs

Faster heating + auto-discharge cuts batch cycle 30-40%.

Real Production Applications

See where this machine fits in real factories.

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

Machine Configuration

Industrial-grade components from established global brands — every part traceable.

Component	Brand / Spec	Detail
PLC Controller	Siemens S7-1200	Industrial-grade PLC, 24/7 reliability, remote-monitor ready.
HMI Touch Screen	Siemens / Weintek	10-inch color HMI, multi-language menu, recipe storage.
Steam Solenoid Valve	Burkert / SMC	Closed-loop pressure regulation, ±0.01 MPa accuracy.
Weighing System	Mettler Toledo	Electronic load cell, ±50 g accuracy across 0-50 kg range.
Agitator Motor	Siemens	5.5 kW VFD-driven, 30-50 rpm continuously variable.
Barrel Material	SUS304	Double-layer 304 food-grade stainless steel, 5+10 mm wall.

Customer Case Studies

Customer details available on request.

Russia Year: 2024

Configuration

2 × PE-1400 + BM-6000 line, 25 t/day

Outcome

Replaced two aging Korean pre-expanders; raw material waste dropped from 12% to 2.5% in first quarter; payback in 14 months.

Egypt Year: 2025

Configuration

1 × PE-1400 + SM-1400 packaging line

Outcome

Local home-appliance OEM cut packaging cost 18% by switching from imported molded foam to in-house production.

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.

ROI Snapshot

Quick reference numbers — for a precise quote with your factory data, use the ROI Calculator.

Equipment Investment

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

Payback Period

12-15 months at 700-900 kg/h continuous operation

Throughput

Up to 7.2 tons/day single-shift, 14+ tons/day double-shift

Run Detailed ROI Calculator →

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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