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EPS blocks and sheets manufacturing equipment

Clinker Panel

Insulated Concrete Forms (ICF) manufacturing equipment

Molded styrofoam

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:

CLOSED-TYPE BLOCKMOLD 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

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

OPEN-TYPE BLOCKMOLD

Производство блока пенопласта неограниченой длины

The internal volume is comprised of a process chamber and a cooling compartment. A block is molded inside the process chamber and is then transferred to the cooling comparment by a push rod driven by the pneumatic cylinder. New batch of material is fed to the empty process chamber, and the molding cycle repeats.   

The machine operates in a batch/continuous mode. A section of the block molded during each cycle in the process chamber is sintered onto the previously molded block inside the cooling compartment. The strength of this joint is virtually the same as the strength of the body of the block. In this way, the machine produces an endless (in theory) bulk of expanded polystyrene cut into blocks of required lengths. Standard guide length is suitable for blocks of up to 2000 mm. This length can be increased to 3000 mm at the customer’s request. 

Open-type blockmold specifications

The structure of this blockmold is patented, Russian patent No 40019. 
Manufacture, sale and use of open-type blockmolds produced by companies or persons other than VyatkaStroyDetal Group is a prosecutable offense. 

Blockmold photo

Блок-форма закрытого типа с ручным управлением.

Блок-форма закрытого типа с полуавтоматической системой управления.

Блок-форма закрытого типа с полуавтоматической системой управления.

Блок-форма закрытого типа с автоматической системой управления.

Production

Production techniques

Production plant

Production area demands

Equipment

Preexpander

Silo bunkers

Blockmold

Vacuum system

EPS cutter

Prebreaker / grinder

Steam boiler

Steam accumulator

Dryer

Pneumatic conveying system

Packing machine

Production line variants

40 sq. m. output

55 sq. m. output

60 sq. m. output

Prices

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How to find us?

Address: Russia, Kirov, ul. Proizvodstvennaya, 21a
Telephone: +7 (8332) 522-661, 521-121, 252-861
Fax: +7 (8332) 511-445, 51-33-22
E-mail: info@v-s-d.ru

 

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