PVC Single-Layer / Multi-Layer Insulated Corrugated Sheet / Roman Tile Extruder Line

This extrusion line is specifically used to produce PVC corrugated roof sheets, Roman-style synthetic tiles, and multi-layer insulation boards. According to the technical specifications, different models meet production requirements as follows:
SJZ80/156 & SJZ65/132 (width 1140mm, output 300-400 kg/h):
Best suited for large agricultural and industrial roofing. A Vietnamese greenhouse builder uses this line to produce 1.14m wide single-layer corrugated sheets, covering 50,000 m² per month. The wide format reduces the number of overlaps, cutting installation time by 20%.
SJZ80/156 & JW550/30 (width 850mm, output 300-400 kg/h):
Ideal for Roman tiles and decorative wall panels. A Philippine roof tile supplier uses this model to produce multi-layer (air cavity) tiles, achieving 30% better thermal insulation than single-layer sheets. The narrower width ensures perfect interlocking for residential roofing.
SJZ92/188 & JW565/30 (width 880mm, output 400-600 kg/h):
High-output solution for export-oriented factories. A Nigerian customer runs three shifts around the clock, producing 2.0mm thick corrugated sheets at 500 kg/h – enough for 8,000 linear meters per day – supplying a housing project across West Africa.

Each line undergoes a 5-stage QC protocol before shipment. The actual test procedures and measurable standards are as follows:
Stage 1: Component Inspection
Screw/barrel hardness: ≥68 HRC (Rockwell), verified by eddy current testing.
Heating bands: Check for uniform thermal expansion at 200°C – no cold zones allowed.
Stage 2: No-Load & Load Test (at factory)
Parameter validation: Run at full load (55kW/110kW) for 6 hours.
Example: SJZ92/188 must run continuously at 550 kg/h for 4 hours, with motor current fluctuation ≤ ±5%.
Extruder stability: Melt pressure variation ≤ ±1.5 MPa (measured at the die).
Stage 3: Product Dimensional QC
Width accuracy: Laser micrometer – tolerance of ±1mm for 1140mm sheets.
Corrugation height check: Profile gauge every 50 meters – e.g., pitch 30mm ±0.3mm.
Multi-layer adhesion strength: Peel test per ASTM D903 – minimum 3.5 N/mm for A/B layers.
Stage 4: On-Site Commissioning (customer factory)
Material test: Run 2 tons of standard PVC dry blend (CaCO₃ 8 phr, CPE 6 phr).
Record actual output: Must reach ≥95% of nominal capacity (e.g., 380 kg/h for 400 kg/h spec).
Cooling tank calibration: Exit sheet temperature ≤40°C to prevent warping.
Stage 5: Long-Term Reliability
24-hour continuous run test: Line runs non-stop after installation – record parameters every 30 minutes.
Actual case: A Saudi Arabian line showed a 0.5% output drop after 24 hours, well below the 2% tolerance.

Q1: Can I produce both single-layer and multi-layer sheets on the same line?
A: Yes, all three models support interchangeable dies. For multi-layer production, you need an additional co-extruder (JW series optional).
Example: An Indonesian customer runs SJZ80/156 + JW550/30 – 8 hours producing single-layer (for economy roofing), 8 hours producing A/B/A multi-layer (for premium villa tiles).

Q2: How can I achieve 600 kg/h on the SJZ92/188? My line only reaches 450 kg/h.
A: Check three aspects:
Screw speed – must be 38-42 RPM (do not go higher to avoid melt fracture).
Formulation – increase CPE to 8 phr and external lubricant to 1.2 phr to improve flow.
Feed zone – ensure barrel fill rate at 70% (use starve feeder with input 510-530 kg/h).
Practical fix: A Turkish customer adjusted screw speed from 48 RPM down to 40 RPM and added a gravimetric blender – output jumped from 470 kg/h to 580 kg/h.

Q3: How often do I need to replace the screw and barrel?
A: For non-corrosive PVC formulations (no residual HCl), expect 18-24 months of continuous operation. Signs: output drop >15% or black specks on products.
Case: A Russian winter roofing factory replaced after 26 months (had processed 9,800 tons) – wear depth only 0.25mm, still within the 0.5mm limit.

Q4: The edges of 1140mm wide sheets are warping. What went wrong?
A: Common cause: uneven cooling. Set cooling tank rollers so the center is 0.5mm higher than the edges. Also, check vacuum on the calibrating table – edge zones require 5-10% higher vacuum than the center (e.g., -0.6 bar at edges, -0.55 bar at center).
Solution implemented for a Brazilian customer: added edge cooling fans (2 x 120W) – warpage reduced from 8mm/m to below 2mm/m.

Q5: Can this line use recycled PVC?
A: Yes, but for single-layer sheets recycled content is limited to 30%; for the middle layer of multi-layer sheets, 40-50% is possible. Fines (below 3mm) must be pelletized, and add 2% virgin stabilizer.
Validated: A Colombian roof producer uses 45% post-consumer window frame recyclate in the core layer – still passes UV resistance test (1000h QUV test, ΔE<3).

Q6: Can the same equipment produce both single-layer and multi-layer tiles?
A: Yes. All three models support die changes for production. To achieve a multi-layer structure (e.g., A/B/A three layers), you need to add an additional co-extruder (compatible with JW series).