PVC Foam Board, Wood Veneer Panel and Carbon Crystal Board Extruder Line

1. PVC Foam Board – Signage and Construction
Use case: A Vietnamese signage manufacturer uses the celuka line (SJZ80/156) to produce 1220×2440 mm, 5-10 mm thick foam boards for indoor signage. The 75 kW motor and 350 kg/h output allow them to replace imported boards, reducing material costs by 22%.
Typical end products:
Exhibition display boards
PVC ceiling panels
Insulated wall panels

2. Wood Veneer Panel – Furniture and Decoration
Use case: A Turkish furniture factory adopted the co-extrusion line (SJZ65/132 + SJZ80/156). They co-extrude a 0.5 mm wood-grain PVC layer onto a 16 mm foam core. The 1600 mm width allows direct production of wardrobe back panels without splicing. Output reaches 480 kg/h, saving 30% of lamination costs.

3. Carbon Crystal Board – High-End Heat and Moisture Resistance
Use case: A Russian underfloor heating system supplier uses the same co-extrusion line to produce 6-8 mm thick carbon crystal boards. The boards passed a 80°C thermal cycle test (1000 hours) and are now sold as a waterproof, non-toxic alternative to plywood in bathrooms and kitchens.

Additional practical benefits
Lower density control – The line can produce boards with densities from 0.45 to 0.75 g/cm³. A Chilean customer reported an 18% reduction in weight per pallet, saving freight costs.
Easy color change – The quick-release screw design reduces cleaning downtime from 4 hours to 1.5 hours (verified by a Polish customer).

To ensure that the produced boards consistently meet global standards (ASTM, EN, GB/T), this extrusion line implements the following 5-step quality control protocol.
Step 1 – Raw Material Verification
Tests: Moisture content of PVC resin (<0.3%) and particle size of blowing agent.
Tools: Halogen moisture meter + sieve shaker.
Real case: Following our advice, a Malaysian customer reduced bubble defects by 85% after adding a pre-drying hopper.
Step 2 – In-line Density and Thickness Monitoring
Method: Ultrasonic sensors installed at the calibrator outlet and cooling tank inlet.
Tolerances: Density ±0.02 g/cm³; thickness ±0.1 mm.
Alarm: Automatic speed reduction if deviation exceeds 2% for more than 10 seconds.
Step 3 – Surface Defect Inspection (Vision + Laser)
Laser scanners detect pinholes, scratches, and uneven celuka layers.
Rejection threshold: Any defect >0.5 mm² within the first 100 meters triggers die gap adjustment.
Step 4 – Mechanical Property Sampling (Per Shift)

Step 5 – Post-Production Aging Tests (Weekly)
UV aging: 72 hours in QUV tester (UVA-340, 0.89 W/m²·nm) – color difference ΔE <3.
Thermal cycling: -20°C ↔ 60°C, 10 cycles – no cracking or delamination.
Real case: Based on the above tests, we helped a South African customer adjust their calcium carbonate filler ratio from 35% to 28%, after which their product produced on the co-extrusion line passed SABS certification.

Q1: Can I produce both solid carbon crystal boards and PVC foam boards on the same line?
A: Yes, but the screw needs to be changed. The SJZ80/156 is a versatile conical twin screw. For solid boards (density >1.2 g/cm³), use a high-compression-ratio screw; for foam boards (density 0.5–0.8 g/cm³), use a barrier screw with a mixing section. We supply both screws along with a 2-hour changeover guide.

Q2: How can I achieve the claimed 500 kg/h output on the co-extrusion line?
A: A Belgian customer consistently achieves 510 kg/h under three practical conditions:
Cooling water temperature: 12–15°C (using a chiller, not cooling tower water).
Die lip opening: set to 1.1 times the final thickness (e.g., 13.2 mm for a 12 mm board).
Main screw speed: 32–35 rpm; feed screw speed synchronized within a 3% difference.

Q3: The maximum width is 1600 mm. Do I need special downstream equipment?
A: The calibrator, puller, and cutter are all compatible with 1600 mm width. However, for boards thicker than 20 mm, we recommend adding an optional six-roll cooling rack to prevent edge sagging – learned from a Spanish customer who initially found edges 2 mm thinner at 25 mm thickness.

Q4: What is the energy consumption per ton?
A: Measured on the celuka line (75 kW motor, 350 kg/h output): average 215 kWh/ton (including main motor, heating, and vacuum calibration). For the co-extrusion line (37+75 kW, 450 kg/h output): 195 kWh/ton, because the auxiliary extruder runs at a lower load. Using VFDs on the main motors saves an additional 12-15%.

Q5: How often does the screw need to be rebuilt?
A: With suitable materials (no heavy calcium-filled waste with high recyclate content), the bimetallic screw lasts 8000–10000 hours. A Portuguese customer running 20 hours/day had a rebuild after 14 months (~8400 hours). We stock pre-assembled spare screws to avoid downtime – replacement can be done within 3 hours.

Q6: Can I co-extrude a layer of wood-fiber composite?
A: Yes, but the auxiliary extruder screw needs to be modified to a low-compression-ratio, long-metering-section design (L/D 28:1). A Brazilian customer successfully co-extruded 40% wood flour + PVC onto a 10 mm foam core, achieving a "wood-plastic composite" appearance without adding excessive weight.