Blockmold | Пенолидер

Blockmolding machine

is designed for final expansion of EPS beads.

Preexpanded beads are fed to the blockmold and heat-treated to expand and mold themselves into a styrofoam block inside the molding chamber. Saturated water steam is used as heat transfer medium.

The feeding process is automatic and pneumatically controlled through feeding valves.

The valves are actuated by a pneumatic cylinder (Camozzi, Italy). A vacuum unit is compulsory to ensure that a block is cooled and stable inside the blockmold chamber.

After cooling the block is knocked out either by the pneumatic cylinder, or by compressed air (air cushion) depending on the type of the blockmold.

We manufacture two types of BLOCKMOLDS: closed and open.

The customers have an option to select the material of the inside surface: high quality carbon steel or stainless steel.

The principal difference between these types of blockmolds is EPS block dimensions and capacity.

is designed for final expansion of EPS beads.

Preexpanded beads are fed to the blockmold and heat-treated to expand and mold themselves into a styrofoam block inside the molding chamber. Saturated water steam is used as heat transfer medium. The feeding process is automatic and pneumatically controlled through feeding valves.
The valves are actuated by a pneumatic cylinder (Camozzi, Italy). A vacuum unit is compulsory to ensure that a block is cooled and stable inside the blockmold chamber.

After cooling the block is knocked out either by the pneumatic cylinder, or by compressed air (air cushion) depending on the type of the blockmold. We manufacture two types of BLOCKMOLDS: closed and open.

The customers have an option to select the material of the inside surface: high quality carbon steel or stainless steel.The principal difference between these types of blockmolds is EPS block dimensions and capacity.

CLOSED-TYPE BLOCKMOLD

The operating chamber comprises the whole internal volume of the blockmold. The molding cycle includes the following stages:

feeding — molding — cooling — knockout

As soon as the vacuuming (cooling) cycle is over, the end door opens and the finished EPS block is knocked out by compressed air onto a trolley to be transported to the sheet cutting area. The main advantage of this blockmold over the open-type one is higher capacity owing to a larger operating chamber (2,5 to 3 times as large, depending on the modification). The drawback is than the length of blocks is limited.

We can manufacture off-standard size blockmolds at the customer’s request..

Specifications
(applicable to grade 25 EPS)

№ пп	Parameter	BF-12	BF-15	BF-16	BF-18	BF-20	BF-22
№ пп	Parameter	closed-type
1	Finished block dimensions(post-cut), mm., : height thickness thickness	1000 630 2000	1200 630 2000	1000 630 2500	1000 600 3000	1200 600 2700	1200 600 3000
2	Capacity per cycle, cub.m	1,26	1,5	1,6	1,8	1,95	21,6
3	Capacity per 8 hour shift, cub.m (depends on the number of automatic options available)	60-120	60-120	70-120	150-200	175-225	200-250
4	Block grade according to EN 13163:2009	15, 25, 35, 50
5	Operating steam pressure Pg inside the steam jacket of the blockmold, MPa (atm), max	0,03 (0,3)
6	Steam temperature inside the process chamber, °C	104...108
7	Steam flow rate required for molding including preexpansion (for max capacity), kg/hour	250*	250*	300*	300*	500*	500*
8	Feeding valve configuration	pneumatic **
9	Knockout unit configuration	compressed air cushion**
10	Rated operating pressure of pneumatic cylinders, atm	10
11	Serviced by, operators	1
12	Dimensions, mm: width х length х height	935 2240 2285	935 2240 2485	935 2740 2285	935 3500 2285	935 3200 2485	935 3500 2485
13	Weigth, kg	1700	1900	2100	2200	2350	2500
Remarks: * Steam generating equipment has to be able to support operating pressure of 5 to 6 atm and generate at least 200-300 kg of steam per hour; **CAMOZZI (Italy) brand pneumatic cylinders. A compressor of Pg =10 atm, min. capacity 0,16 cub.m/min, receiver volume 60L is required for the normal operation of the pneumatic system.

PRESS BLOCKMOLD

Our latest design (2015). The FVS 11.104 blockmold is designed for manufacture of EPS blocks from preexpanded virgin beads or from recycled (ground) beads. The blockmold supports two modes:

— regular mode: a styrofoam block is made inside the blockmold from preexpanded EPS by hot steam treatment;

— recycled mode: recycled EPS is heat-treated and compressed by means of a movable plate.

EPS block molding from virgin raw material

EPS block molding from virgin raw material (expandable polystyrene beads).

EPS block molding from recycled material

EPS block molding from recycled material (ground EPS).

The next stage is stabilization by vacuum. The finished product is knocked out by air cushion. Process media flows (steam, vacuum, compressed air) are directed and distributed by pneumatically controlled dampers and valves.

Automation option — semi-automatic.

For more information on how to produce styrofoam from recycled material click here.

Press Blockmold specification

Parameter	Value
Process chamber	1260×652×1038 mm, incl. adjustable to 1260 mm
Dimensions of a non-pressed block from virgin material	1260…1000×652×1038 mm
Dimensions of a pressed block from recycled material	800…300×652×1038 mm
Maximum process chamber volume	0,853 cub.m
Maximum density of the finished product	60 kg/cub.m
Maximum push rod speed	2 m/min
Dimensions: length width height	3880 mm 1580 mm 4000 mm
Weight, kg	1805 kg.
Electric specifications
Supply current type	alternating, three-phase
Rated current frequency	50 Hz
Rated supply voltage	380 V
Rated power	4 kW