Pré-Expansora em Lote PE-1800 — eps pre-expanders by ChinaEps, CE & ISO 9001 & ISO 14001 certified.
A PE-1800 é uma pré-expansora em lote de serviço pesado, construída para produção de EPS de alto volume. Com produção de 1.400-1.700 kg/h e barril de 1.800 mm, possui controle automático de densidade e integração SCADA para gestão contínua da linha de produção. Ideal para fábricas com operação 24/7.
CE + ISO 9001 + ISO 14001 (environmental management)
* 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
Fábricas de médio porte que ultrapassam a PE-1400 atingem o teto de capacidade em torno de 14 t/dia
Como Esta Máquina Resolve
A PE-1800 eleva o teto para 30+ t/dia com capacidade de 1.300-1.600 kg/h no mesmo espaço de fábrica de um único pré-expansor, sem necessidade de adicionar uma segunda máquina.
O Problema
Cilindro maior normalmente significa mais desperdício de vapor por kg de pérola
Como Esta Máquina Resolve
Isolamento de dupla camada + recirculação otimizada de vapor a 0,20-0,28 MPa mantém o consumo de vapor por tonelada em 220-260 kg — comparável à PE-1400 menor, e não 50% mais.
O Problema
Em capacidades mais altas, ajustes manuais de umidade e densidade fazem cada turno desviar
Como Esta Máquina Resolve
Sensor de umidade online + malha de feedback automático de densidade — operador define o alvo uma vez, máquina se autocorrige durante o turno; sem necessidade de intervenção manual.
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.
The high-capacity expansion chamber for 1,400-1,700 kg/h throughput. 1,800mm diameter accommodates larger batch sizes, and the 60mm mineral-wool insulation cuts heat loss 40-50% vs single-layer barrels — critical for 24/7 lights-out operation economics.
Engineering Details
1,800mm diameter, 304 stainless inner shell + 60mm mineral wool + steel outer shell. Working pressure rating 0.5 MPa (2× operating). Pre-heat 12-15 minutes from cold start. Conical bottom for clean discharge of FR-additive-heavy batches.
2. Multi-Zone Steam Injection (8 Ports)
Function
The signature PE-1800 differentiator: 8 steam injection ports vs 4 on PE-1400. Uniform steam distribution across the larger 1,800mm barrel volume is what holds ±0.3 kg/m³ density on FR-EPS — flow concentration causes hot spots that wreck density uniformity.
Engineering Details
8 pneumatically actuated control valves arranged radially around the barrel. Each port independently PLC-controlled. Closed-loop pressure regulation per zone at 0.20-0.25 MPa. Steam recycling loop captures condensate back to boiler — energy savings 30-35% over single-zone designs.
3. Heavy-Duty 4-Blade Agitator (11 kW)
Function
Continuously stirs the larger batch volume of expanding beads with the higher torque needed for dense FR/graphite EPS. 4-blade design + dual bearings handle 35-45 kg/m³ material that bog down 3-blade agitators.
Engineering Details
4-blade 316 stainless agitator with dual lower bearings. 11 kW SEW Eurodrive motor + 25:1 worm reducer. Variable-frequency speed control 12-40 RPM via VFD. Mechanical seal rated 12,000+ hours; replaceable from below without dismantling.
4. Premium Electronic Weighing System
Function
Pre-weighs each batch with ±30g accuracy (tighter than PE-1400's ±50g). The factor-of-two improvement in weighing precision directly contributes to the ±0.3 kg/m³ density variance spec.
Engineering Details
±30g accuracy via German HBK or Mettler-Toledo load cells (5-15 kg range). Pneumatic gate valve releases pre-weighed batch into barrel. PLC stores 50+ density recipes; switching from FR-graphite to standard EPS takes 30 seconds with audit-trail logging.
5. SCADA-Integrated PLC + HMI
Function
Supervises every parameter in real time AND exports production data to upstream MES/ERP systems. Critical for premium QC-critical contracts that demand digital audit trails.
Engineering Details
Siemens S7-1500 PLC with extended I/O (24 DI / 16 DO / 4 AI). Weintek MT8121iE 12.1" HMI with multilingual UI. SCADA gateway with Ethernet/IP, OPC UA, Modbus TCP. Local fault log retains 10,000 events; auto-export to MES via configurable triggers.
6. Integrated Fluidized Bed Dryer
Function
Built-in (not optional like PE-1400) — gently dries freshly expanded beads before aging. Removes surface moisture that causes clumping during aging and downstream molding rejects.
Engineering Details
Larger-capacity fluidized chamber matched to 1,400-1,700 kg/h throughput. Hot-air flow at 40-55°C; bead dwell 6-12 minutes. Cyclone separator captures fines. Thermal-imaging sensors monitor bed temperature uniformity in real-time.
7. High-Capacity Pneumatic Conveying
Function
Moves expanded beads from the discharge point to multiple aging silos (10-50m away) at the higher PE-1800 throughput rate. Sized to keep up with 1,700 kg/h peak discharge.
Premium safety for FR-EPS production — graphite-EPS dust is combustible per ATEX zone-22 classification. Triple redundant safety prevents the kind of dust-fire incident that costs an FR producer their certification.
Engineering Details
CE per EN 60204-1 + EN ISO 13849-1 PLe (higher than PE-1400's PLd). Pressure relief at 0.35 MPa setpoint. Steam pressure interlock prevents agitator start. Thermal cutoff at >60°C. ATEX zone-22 grounding straps and explosion-proof junction boxes. Anti-static dust extraction with HEPA-grade filter.
Princípio de Funcionamento
A PE-1800 segue a mesma física de expansão da PE-1400, mas com cilindro de 1.800 mm e malha de recirculação de vapor mais agressiva. PLC em malha fechada, sensores de umidade e densidade online, e rosca de descarga estendida lidam com o maior fluxo de massa sem sacrificar a tolerância de densidade.
Step 1
1. Alimentação
Até 100 kg por lote; alimentação automática a partir do silo de pérolas brutas.
Step 2
2. Injeção de Vapor
Vapor saturado 0,20-0,28 MPa; agitador 25-45 rpm.
Step 3
3. Expansão
Densidade-alvo 10-30 kg/m³; ciclo 100-130 s.
Step 4
4. Sensoriamento Online
Sensores de umidade + densidade enviam feedback ao PLC a cada 5 s; autocorreção.
Step 5
5. Descarga
Descarga pneumática para silo de maturação estendido.
Vantagens de Desempenho Engenheiradas
Cada vantagem respaldada por especificações mensuráveis — sem alegações de marketing sem dados.
Capacidade
1,300-1,600 kg/h
vs vs PE-1400 at 700-900 kg/h
80% de aumento de capacidade; uma PE-1800 substitui duas PE-1400 em muitas configurações.
Eficiência de Vapor
220-260 kg/ton
vs industry typical 320-400 kg/ton
30% menos consumo de vapor por tonelada de pérola expandida.
Tolerância de Densidade
±0.6 kg/m³
vs industry typical ±2-3 kg/m³
Sensores online + PLC em malha fechada mantêm a saída dentro de tolerância estreita mesmo a 1.500+ kg/h.
Capacidade Anual
4,500-5,500 tons
vs two-shift operation
Uma única PE-1800 dimensionada para fábricas de EPS de médio-grande porte com receita anual de USD 8-12 milhões.
Aplicações Reais de Produção
Veja onde esta máquina se encaixa em fábricas reais.
Flame-retardant graphite EPS bead production for high-rise hospital and school construction — Class B1 fire rating
Premium external wall insulation system (EWI) production at 30-40 kg/m³ for energy-retrofit projects
Industrial cold storage panel production requiring ±0.3 kg/m³ density consistency batch-to-batch
24/7 high-volume EPS insulation board production for export markets — 8,000-12,000 tons annual output
QC-critical EPS bead production with SCADA-logged audit trail for ISO 9001 / ISO 14001 traceability
Vertically integrated premium EPS line — PE-1800 feeds BM-1800 block molding and SPB-Q cutting
Configuração da Máquina
Componentes de grau industrial de marcas globais consagradas — cada peça rastreável.
Componente
Marca / Especificação
Detalhe
Controlador PLC
Siemens S7-1500
PLC de alta gama, ciclo rápido, suporta OPC-UA para monitoramento remoto.
Tela Sensível ao Toque HMI
Siemens TP1200 Comfort
HMI colorido de 12 polegadas, gerenciamento de receitas, registro multi-turno.
Válvula de Controle de Vapor
Burkert
Válvula angular pneumática, resolução de pressão ±0,005 MPa.
Sensor de Densidade Online
Endress+Hauser
Medição de densidade em tempo real, faixa 0-50 kg/m³.
Sensor de Umidade Online
Sartorius / Sentronic
Sensor capacitivo de umidade, resolução 0,1% RH.
Motor do Agitador
Siemens
VFD 7,5 kW, 25-45 rpm continuamente variável.
Estudos de Caso de Clientes
Detalhes do cliente disponíveis sob solicitação.
BrazilAno: 2024
Configuração
Linha de 1 × PE-1800 + BM-1800 + CM-6000, 35 t/dia
Resultado
Substituiu dois pré-expansores italianos antigos; espaço de fábrica reduzido em 30%, custo de energia caiu 28%; payback em 11 meses na produção plena.
Maintenance & Safety
A clear schedule keeps the line running. Built-in safety systems protect operators and product alike.
Inspect agitator dual bearings for wear. Lubricate 25:1 reducer per SEW spec (NLGI-2 grease, 80g). Drain steam condensate from all 8 zones. Verify load cell calibration with reference weights (5/10/15 kg target). Test e-stop function and ATEX interlocks.
Monthly
Open inspection port; clean barrel interior with food-grade detergent. Inspect 4-blade agitator for wear. Recalibrate steam pressure transducers in all 8 zones (±0.005 MPa target). Service HEPA dust filter on ATEX extraction system. Backup PLC recipes + production logs to USB.
Major overhaul: replace agitator dual bearings (12,000h spec), replace mechanical seal, recalibrate all 8 steam zones, re-certify safety circuit per EN ISO 13849-1 PLe, update Siemens PLC firmware, refresh ATEX-zone-22 operator training including FR-dust handling.
Safety Features
CE certification per EN 60204-1 + EN ISO 13849-1 PLe (higher than PE-1400 PLd) for safety-related control systems
Pressure relief valve at 0.35 MPa setpoint — safely vents if barrel over-pressurizes
Steam pressure interlock + dual interlock on inspection port — prevents agitator start until barrel sealed and pressurized
Three emergency-stop mushrooms — operator panel + machine side + SCADA terminal — Category 0 stop within 80ms
ATEX zone-22 certification for combustible-dust environments — required for FR/graphite EPS production
Anti-static grounding straps + explosion-proof junction boxes for FR-dust handling
HEPA-grade dust extraction filter prevents combustible-dust accumulation in factory air
SCADA-logged audit trail for every safety event with timestamp + operator login + parameter snapshot
Product FAQ
The questions buyers ask most often before placing an order.
How is the PE-1800 different from the PE-1400?
Four key differences: (1) 8 steam injection ports vs 4 — uniform expansion across the larger barrel, holding ±0.3 kg/m³ density vs ±0.5 kg/m³ on PE-1400; (2) Larger 1,800mm barrel = 1,400-1,700 kg/h throughput vs 700-900 kg/h; (3) Premium SCADA integration with MES/ERP export vs PE-1400's USB-only; (4) ATEX zone-22 certification for FR-graphite EPS dust environments. Net: PE-1800 is the sweet spot for premium QC-critical contracts and 24/7 lights-out factories above 8,000 tons/year output.
Does the PE-1800 require an ATEX-rated factory environment?
Only if you process flame-retardant or graphite EPS (which is most premium-insulation production today). The ATEX zone-22 certification on the PE-1800 is a built-in capability — you don't need additional certification of your factory environment. If you only run standard EPS (no FR additives, no graphite), ATEX is overkill but harmless.
What's the actual density variance hold on 40 kg/m³ FR-graphite EPS?
Field measurements on Knauf-style 40 kg/m³ graphite EPS show ±0.25-0.30 kg/m³ typical, well inside the ±0.3 kg/m³ spec. On standard 22 kg/m³ EPS the PE-1800 holds ±0.15 kg/m³. We ship calibration reference samples with every machine for customer-side QC verification.
What steam boiler is required to feed the PE-1800?
Minimum 1.0 ton/h steam boiler at 0.5 MPa working pressure. Most premium factories run a 2-ton/h boiler to cover PE-1800 + BM-1800 block molding + SPB-Q cutting line. ChinaEps can quote the matching boiler + softener + condensate-return system.
Can SCADA integrate with my existing MES / ERP system?
Yes — the PE-1800 SCADA gateway supports Ethernet/IP, OPC UA, and Modbus TCP out of the box. We have customer integrations with SAP, Microsoft Dynamics, Plex, and several regional ERP systems. Initial integration takes 1-2 weeks of engineering work — quoted as part of the project.
How long is the dual-bearing agitator service life on FR-EPS?
Rated 12,000+ hours (~3-4 years single-shift). Dual-bearing design eliminates the single-point failure of PE-1400's single-bearing agitator. Replacement is a 4-hour job accessible from below without dismantling the barrel. Spare bearing kit ships with every machine.
Does the PE-1800 ship to 220V/60Hz markets?
Yes — factory build option. We swap motor (SEW 220V/60Hz), VFD, contactors. PLC and HMI are voltage-flexible. No price difference; 3-week lead time adjustment.
What is the cycle time, and batches per hour?
Cycle time 3-5 minutes per batch (faster than PE-1400 due to higher steam capacity and 8-port injection). At 4-minute average cycles, PE-1800 runs 15 batches/hour = 1,500 kg/h finished beads at 100 kg/batch. Two-shift operation easily reaches 30+ tons/day, 4,500-5,500 tons/year.
What is the floor-space requirement for installation?
Machine footprint: 3,500 × 2,800mm + 5.5m height. Add 2m service clearance on each side for maintenance access = installation area ~8m × 5m × 6m height. Steam line + electrical cabinet adds another 4m² adjacent. Most customers install the PE-1800 + fluidized dryer + aging silos in a 200-300m² dedicated bay.
How is the PE-1800 packed and shipped?
One 40HQ + one 20FT container fits the PE-1800. Barrel ships fully assembled (8 steam manifold valves are pre-installed and tested). All steel surfaces oil-coated and shrink-wrapped against salt-air. ATEX-rated electrical components in foam-lined hermetically-sealed crates. Total shipping weight ~10,500 kg.
Build a Complete EPS Line
This machine integrates into the full ChinaEps production flow — upstream, downstream, and auxiliary equipment from one supplier.
