PVC Door Panel Extrusion Line

These lines are designed to produce solid or foamed PVC door panels, with applications including:
Interior residential doors (bathroom, bedroom, kitchen)
Commercial partition doors (offices, hotels, hospitals)
Cabinet and wardrobe door panels
Decorative wall panels and baseboards
Thanks to the maximum product widths (800 mm, 1000 mm, 1250 mm), manufacturers can easily produce standard door sizes without secondary lamination or welding.
Real case – Poland
A door and window factory in Poznań, Poland installed a YF1000 line (max width 1000 mm) to produce 950 mm wide hollow PVC doors. Actual extrusion output is about 420 kg/h (rated 450 kg/h). They run two shifts, producing over 8,000 door panels per month. The accompanying calibration table and downstream haul-off ensure perfect flatness – critical for hinge and lock installation.

2.1 High output – lowers cost per kg

The SJZ conical twin-screw extruder provides high torque and stable plasticization. For example, the YF1250 achieves 500 kg/h with the same 110 kW power, an 11% output increase over the YF1000 at unchanged power consumption. This means lower energy consumption per ton of product.

2.2 Wide product range – one line, multiple sizes
Adjustable dies and calibration tables allow switching between different door panel widths within the line’s maximum width. A customer in Turkey uses the YF1250: producing 800 mm door panels in the morning (high speed) and 1200 mm panels in the afternoon – changeover time less than 45 minutes.

2.3 Optimized utilities – saves water and air

These values are actual consumption at full load, not theoretical maximums. Many competitors give higher figures. Our closed-loop water cooling system reduces water waste – a real advantage in water-scarce regions (e.g., South Africa, Australia).

We implement a 4-stage quality control protocol to ensure every extrusion line produces consistently stable door panels.

Stage 1 – Raw material verification
PVC resin and additives (CaCO₃, stabilizers, foaming agents) are tested for moisture content (≤0.3%) and particle size distribution.
Hot mix compound is checked for gel time and melt stability using a torque rheometer.

Stage 2 – Online monitoring
Laser width and thickness gauges are installed after the calibration table. Tolerances: thickness ±0.1 mm, width ±0.5 mm. Out-of-tolerance triggers an automatic alarm.
Extruder melt pressure and temperature are recorded every second. For the SJZ 92/188, we keep melt pressure between 2530 MPa and temperature profile within ±2°C.

Stage 3 – Physical & mechanical testing (per shift)
We cut samples from production batches for testing:
Impact resistance (Izod or drop hammer) – target ≥8 kJ/m² for foamed panels.
Flexural strength (ASTM D790) – typically ≥35 MPa.
Heat deflection temperature (HDT) – above 70°C for indoor use.
Dimensional stability (after 24 h at 70°C) – shrinkage <0.5%.

Real case – Vietnam
A customer exporting door panels to the Japanese market required warpage ≤0.3% for 2000 mm long door panels. Our YF1000 line passed the test by adjusting the cooling tank water temperature from 25°C to 18°C. We recorded the entire set of parameters and provided a process recipe card for the customer’s operators.

Stage 4 – Long-term reliability run
Before shipment, each complete line runs continuously for 8 hours using the customer’s target formulation. We record vibration (≤0.05 mm/s at the gearbox), check screw wear via magnetic plugs, and final door panel quality.

Q1: Which model should I choose – YF800, YF1000 or YF1250?
YF800 (320 kg/h, 800 mm width): Best for small workshops or producing narrow panels (e.g., louver doors, cabinet doors). Lower initial investment.
YF1000 (450 kg/h, 1000 mm width): Most popular model for standard residential door panels (finished width up to 900-950 mm). Good balance between output and utility cost.
YF1250 (500 kg/h, 1250 mm width): Suitable for large factories producing wide door panels (e.g., 1200 mm commercial doors) or multiple widths on one line. Higher output lowers labor cost per panel.

Q2: Can the same screw set be used for both solid and foamed PVC?
Yes, the SJZ conical twin-screw is designed for both. However, you need to adjust the compression ratio by changing screw elements (we provide a spare set for foaming). For customers switching formulations weekly, we recommend purchasing an additional screw set – cost recovered within 3 months through faster changeovers.

Q3: How much floor space do I need?
Approximate line length (from feeding to stacking table):
YF800: 18 meters
YF1000: 22 meters
YF1250: 24 meters
Minimum width: 3.5 meters (for operator access).

Q4: What is the typical power consumption per ton?
Based on real customer data:
YF800: approx. 170-190 kWh/ton (320 kg/h @55 kW = 172 kWh/ton theoretical)
YF1000: approx. 245 kWh/ton (450 kg/h @110 kW)
YF1250: approx. 220 kWh/ton (500 kg/h @110 kW)
The YF1250 has the lowest energy consumption per kg because of higher output with the same motor power.

Q5: How often should I replace the screw and barrel?
With proper maintenance (regular cleaning, no metal contaminants), the SJZ 92/188 screw has a service life of 18,000-22,000 hours. The bimetallic barrel liner typically lasts 25,000 hours. We stock replacement parts for next-day shipment.

Q6: Do you provide on-site training?
Yes. Our engineers stay at your factory for 5-7 working days to:
Install and commission the line
Train operators and maintenance staff
Produce the first batch of qualified door panels
Leave a detailed troubleshooting guide