1. Customer Profile
A large chemical new material enterprise in Central China, mainly engaged in the research and production of mineral stone powder based environmentally friendly filling masterbatch, deeply cultivating the field of green building materials raw materials. It has purchased two sets of customized twin-screw granulation production lines for the large-scale production of PP+mineral powder masterbatch, meeting the demand for special raw material orders for hollow boards.
2. Customer pain points
The original equipment has poor feeding accuracy, large errors in the ratio of powder and granular materials, uneven density and toughness of finished masterbatch, and is prone to fracture and brittleness problems;
The production capacity of the old line is only 300-500kg/h, far below the minimum production capacity requirement of 1.5 tons/hour for orders, resulting in low production efficiency and long order delivery cycles;
The level of equipment automation is low, relying on manual batching and debugging, resulting in high labor costs, and significant fluctuations in product quality between batches, making it difficult to consistently meet industry standards QB/T 1126-2021.
3. Solution
Based on the material characteristics of PP+mineral powder (1200 mesh), customize two sets of differentiated twin-screw granulation production lines to accurately match experimental research and development and large-scale production needs:
3.1 Experimental production line configuration (KLWE-35B)
Core equipment: KLWE-35B twin-screw extruder (aspect ratio 64:1), suitable for small batch trial production of 60-120kg/h;
Feeding system: 4 sets of weight loss feeders (3 sets of calcium powder/phosphogypsum powder+1 set of small material)+2 sets of particle feeders, with a ratio accuracy controlled within ± 0.5%;
Cooling granulation: 3-meter water trough+6-meter air-cooled conveyor belt+gantry granulator, ensuring uniform shaping of small batches of particles.
3.2 Mass production line configuration (KLWE-75H)
Core equipment: KLWE-75H high twist twin-screw extruder (aspect ratio 70:1), 415KW high-power host, suitable for mass production of 1.5-2 tons/hour;
Feeding system: 6-component automatic feeding system+6 sets of high-precision weight loss feeders, equipped with Mettler Toledo weighing sensors, with a proportioning error of ≤± 0.3%;
Cooling granulation: 4-meter water passing conveyor belt+24 meter air-cooled conveyor belt+vibrating screen, achieving continuous and standardized production;
Control system: 15 inch touch screen PLC intelligent control, integrated with real-time monitoring of temperature, pressure, and flow, and fully automated operation.
4. On site display
5. Operation effect
Capacity leap
The stable production capacity of the experimental line has reached 100kg/h, and the actual production capacity of the mass production line has remained stable at 1.8 tons/hour, an increase of over 260% compared to the old line, exceeding the customer's capacity target of 1.5 tons/hour;
Accuracy upgrade
The material ratio accuracy has been improved from the old line of ± 3% to ± 0.3%, and the mineral powder filling rate has remained stable at 84% ± 0.5%. The particle size is uniform and the toughness is strong, fully meeting industry standards;
Efficiency optimization
Achieve full process automation and continuous production, reduce 70% manual intervention, achieve 99% quality consistency between batches, and shorten order delivery cycles by 40%;
Stable and durable
The equipment has a continuous and fault free operation time of over 8000 hours, and the core components are guaranteed for 1 year, reducing maintenance costs by 35%.
6. Customer reviews
The entire production line is fully adapted to the production needs of mineral powder filled masterbatch, with precise feeding and stable operation. The production capacity and product quality far exceed expectations, effectively solving the core problems of insufficient production capacity and uneven finished products in old lines, helping enterprises seize the market share of green building materials, and cooperating with professional expertise efficiently. It is worthy of long-term trust!
7. Consultation entrance
Get customized solutions for the same type of twin-screw granulation production line for filling masterbatch>