Pré-Expansor Automático EPS por Lotes - fabricante de máquinas EPS China

PE-1400

CE ISO 9001

Pré-Expansor Automático EPS por Lotes

Name: Pré-Expansor Automático EPS por Lotes
Brand: ChinaEps
Availability: PreOrder

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Pré-Expansor Automático EPS por Lotes — eps pre-expanders by ChinaEps, CE & ISO 9001 certified.

Fabricamos o pré-expansor EPS em lote PE-1400 — 700-900 kg/h, precisão ±0,5 kg/m³, integração SCADA. Certificado CE, 60+ países.

Especificações Principais

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)

Certificado CE e ISO 9001 Garantia Estrutural 5 Anos Resposta Técnica em 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.

Especificações Técnicas

4 models

Parâmetro	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)

* As especificações estão sujeitas a alterações sem aviso prévio. Entre em contato para obter os dados técnicos mais recentes.

O Que Esta Máquina Resolve

Três problemas de produção eliminados por esta máquina — com soluções engenheiradas e mensuráveis.

O Problema 1

Densidade inconsistente da espuma desperdiça 8-15% de matéria-prima por lote

Como Esta Máquina Resolve

A PE-1400 utiliza um sistema de pesagem eletrônica de alta precisão + detecção automática de nível de material para manter a variação de densidade abaixo de ±0,5 kg/m³, reduzindo o desperdício de matéria-prima para 1-2%.

O Problema 2

O controle manual do vapor causa expansão irregular das pérolas e refugos na moldagem de formas

Como Esta Máquina Resolve

A regulagem da pressão de vapor por PLC em malha fechada (0,18-0,23 MPa) mantém a taxa de expansão dentro de ±2 vezes em todos os lotes — a taxa de refugo na moldagem de formas a jusante cai de 6-9% para menos de 2%.

O Problema 3

Aquecimento prolongado + ciclos lentos de lote limitam a capacidade do pré-expansor

Como Esta Máquina Resolve

O cilindro com isolamento de dupla camada + sistema de recirculação de vapor reduz o tempo de aquecimento em 40% e otimiza o tempo de ciclo de 700-900 kg/h em comparação com os designs antigos de camada única.

Princípio de Funcionamento

A PE-1400 expande pérolas brutas de EPS injetando vapor saturado no cilindro de aço inoxidável de 1.400 mm. O PLC controla a pressão de vapor, o tempo de expansão e o peso de descarga; o agitador garante aquecimento uniforme; as pérolas acabadas são descarregadas automaticamente para o silo de maturação.

Step 1

1. Alimentação

Pérolas brutas de EPS carregadas pelo funil de alimentação via pesagem eletrônica (precisão ±50g).

Step 2

2. Injeção de Vapor

Vapor saturado (0,18-0,23 MPa) injetado; agitador gira a 30-50 rpm para expansão uniforme.

Step 3

3. Expansão

As pérolas expandem 40-80×, a densidade cai para 12-30 kg/m³ conforme a receita.

Step 4

4. Descarga

Descarga automática para o silo de maturação quando a densidade-alvo é sinalizada pelo sensor de nível + medidor de densidade.

Step 5

5. Maturação

As pérolas maturam por 8-24 horas em silo de leito fluidizado; prontas para moldagem de formas/blocos.

Vantagens de Desempenho Engenheiradas

Cada vantagem respaldada por especificações mensuráveis — sem alegações de marketing sem dados.

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.

Economia de Energia

25-35%

vs vs traditional single-layer pre-expanders

O isolamento de dupla camada + recirculação de vapor reduz o consumo de vapor por tonelada de pérola expandida.

Variação de Densidade

±0.5 kg/m³

vs industry typical ±2-3 kg/m³

Pesagem eletrônica + PLC em malha fechada mantém cada lote dentro de tolerância estreita — menos refugos a jusante.

Capacidade

700-900 kg/h

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

40% de aumento de capacidade no mesmo espaço de fábrica.

Tempo de Ciclo

90-120 s

vs vs older 150-200 s designs

Aquecimento mais rápido + descarga automática reduz o ciclo de lote em 30-40%.

Aplicações Reais de Produção

Veja onde esta máquina se encaixa em fábricas reais.

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

Configuração da Máquina

Componentes de grau industrial de marcas globais consagradas — cada peça rastreável.

Componente	Marca / Especificação	Detalhe
Controlador PLC	Siemens S7-1200	PLC de grau industrial, confiabilidade 24/7, pronto para monitoramento remoto.
Tela Sensível ao Toque HMI	Siemens / Weintek	HMI colorido de 10 polegadas, menu multilíngue, armazenamento de receitas.
Válvula Solenoide de Vapor	Burkert / SMC	Regulagem de pressão em malha fechada, precisão ±0,01 MPa.
Sistema de Pesagem	Mettler Toledo	Célula de carga eletrônica, precisão ±50 g em faixa de 0-50 kg.
Motor do Agitador	Siemens	Acionado por VFD de 5,5 kW, 30-50 rpm continuamente variável.
Material do Cilindro	SUS304	Aço inoxidável 304 grau alimentar de dupla camada, parede 5+10 mm.

Estudos de Caso de Clientes

Detalhes do cliente disponíveis sob solicitação.

Russia Ano: 2024

Configuração

Linha de 2 × PE-1400 + BM-6000, 25 t/dia

Resultado

Substituiu dois pré-expansores coreanos antigos; o desperdício de matéria-prima caiu de 12% para 2,5% no primeiro trimestre; payback em 14 meses.

Egypt Ano: 2025

Configuração

Linha de embalagem 1 × PE-1400 + SM-1400

Resultado

OEM local de eletrodomésticos reduziu o custo de embalagem em 18% ao migrar de espuma moldada importada para produção própria.

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.

Resumo de ROI

Números de referência rápidos — para uma cotação precisa com os dados da sua fábrica, use a Calculadora de ROI.

Investimento em Equipamento

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

Período de Retorno (Payback)

12-15 meses com 700-900 kg/h em operação contínua

Capacidade

Até 7,2 toneladas/dia em turno único, 14+ toneladas/dia em turno duplo

Executar Calculadora Detalhada de ROI →

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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