PS Foam Picture Frame Extruder Extrusion Line

Thanks to the co-extrusion configuration and built-in hot stamping unit, the line is ideal for producing:
Picture frames for 3R, 4R, 5R, and 8-inch photos
Decorative mouldings with wood grain or metallic finishes
Custom frame profiles for art galleries, exhibitions, and home interior stores
Multi-layer foam profiles with a smooth skin layer over a rigid PS foam core
Real case: A medium-sized picture frame factory in Southeast Asia uses the YF3 model (5inch width, 10 hot stamping units) and produces 5,000 meters of frame line per shift. The co-extruder applies a thin, highgloss PS layer while the hot stamping units add realistic wood grain patterns – all on a single continuous line.

1. Four dedicated models with wide output range

You can select the exact model according to your target product size – no over-investment or capacity waste.
2. Integrated co-extrusion (JW535/JW545)
All models come with a co-extruder (JW535 for YF1, JW545 for YF2–YF4). This enables you to:
Add a different colour or material layer on the surface
Improve surface hardness and scratch resistance
Reduce raw material costs by using recycled PS in the core layer
3. In-line hot stamping – up to 12 stations
The number of hot stamping stations increases with model size (8 → 12). In practical terms this means:
8 stations (YF1): single or two-colour simple patterns
10 stations (YF2/YF3): multi-colour wood grain or marble effects
12 stations (YF4): complex, high-definition patterns on wide frames
Real case: A European customer using YF4 reported that 12 hot stamping heads enable decoration of 8-inch frames with a continuous oak pattern, eliminating a separate off-line printing step and reducing production time by 35%.
4. Stable speed across all models
YF1–YF3: 2–6 m/min (adjustable for different foam densities)
YF4: 3–6 m/min (slightly higher base speed due to wider die design)
This speed range ensures optimal melt flow and cooling for PS foam, preventing surface bubbles or uneven thickness.
5. JW series extruders – proven reliability
Main extruders JW565 / JW590 / JW5100 / JW5120 are specially designed for PS foam. Features include:
Special screw geometry for gentle foaming
Precise temperature control (±1°C)
High torque for consistent output even with recycled material

To ensure consistent frame profiles, each line follows a strict QC protocol. Below is the standard workflow we recommend and support:
1. Incoming material inspection
PS resin: daily check of melt flow index
Blowing agent: purity and moisture content
Masterbatch & hot stamping foil: adhesion test on samples
2. In-process inspection (every 30 minutes)

3. End-of-line inspection
Visual check for scratches, bubbles or missing foil under 1000 lux lighting
Cross-section check – per shift: randomly cut 2 samples, inspect internal cell structure (uniform closed cells, no large voids)
Assembly test – miter cut four profile pieces and assemble into a complete frame; measure diagonal deviation (<1 mm)
4. Long-term reliability tests (monthly)
Heat ageing: 48 h at 60°C, check for warpage or shrinkage (≤0.2%)
Damp heat test: 72 h at 40°C / 95% RH – ensure no blistering or adhesion loss
Real case: A US customer using YF2 reported that after implementing the above QC plan, customer returns due to surface defects dropped from 2.3% to 0.4% within 3 months.

Q1: Can I change product width quickly on the same model?
A: Yes. For example, on YF4 (designed for 6–8 inches), you can switch between 6, 7, and 8 inches by changing the calibrating die and adjusting line speed. Typical changeover time is 45–60 minutes.

Q2: Besides width, what is the difference between YF3 and YF4?
A: YF4 has a larger main extruder (JW5120 vs JW5100), 12 hot stamping stations (vs 10), and a higher minimum speed (3 vs 2 m/min). The wider die and additional stamping heads ensure even decoration on 8inch profiles – something YF3 cannot reliably handle.

Q3: How do I clean the hot stamping rollers after changing colour?
A: While the rollers are warm (60–80°C), wipe with a soft cotton cloth dipped in isopropyl alcohol. Never use metal scrapers. For heavy residue, we supply dedicated silicone cleaning blocks. Most customers can clean each station within 10 minutes.

Q4: I occasionally get bubbles on the frame surface. What could cause that?
A: Three common causes in PS foam lines:
Moisture in resin – dry PS pellets at 80°C for 2 hours
Excess blowing agent – check metering pump calibration
Extruder temperature too high – reduce barrel zone temperatures by 5–10°C
Every machine comes with a detailed troubleshooting card.

Q5: Can I use recycled PS (post–industrial or post–consumer)?
A: Yes, up to 30% in the core layer through the co-extruder. However, do not use recycled PS in the skin layer – it causes unstable hot stamping adhesion. The coextruder on YF2–YF4 is perfect for this “virgin skin / recycled core” structure.

Q6: What is the power consumption of YF4 at full load?
A: Approximately 95 kW, including all extruders, pullers and hot stamping units. The JW5120 main extruder consumes about 65 kW. All control panels come standard with energy monitoring.