I. System Composition & Material Compatibility
Core Module Integration
- Extruder:
- Screw diameter 55–65 mm, L/D ratio 28:1, featuring three-stage design:
- Deep-feed section (anti-bridging for PVC/PE/PP)
- Barrier compression zone (shear control)
- Shallow metering section (pressure stabilization)
- Bimetallic alloy barrel lining (HRC≥60) → ↑300% lifespan.
- Screw diameter 55–65 mm, L/D ratio 28:1, featuring three-stage design:
- Mold System:
- Quick-change die supports 10+ profiles (round rattan: Φ3–20 mm, flat rattan: 8–10 mm width, embossed rattan) → tolerance ±0.05 mm.
- Hydraulic screen changer → zero-downtime swaps (pressure fluctuation <1 MPa).
- Haul-off & Winding:
- Caterpillar-roller hybrid system (silicone belt + chrome-plated rolls) → sync error <0.05% at 60 m/min.
- Magnetic tension winding → adaptive tension 0.5–15 N (for 1–20 mm rattan).
Multi-Material Process Optimization
| Material | Anti-Aging Formula | Process Highlights |
|---|---|---|
| Outdoor PE Rattan | UV stabilizer + 2% antioxidant | Suspended air cooling (0.5–2 m/s) → anti-deformation |
| PVC Embossed Rattan | 15% plasticizer + nano-CaCO₃ | Embossing die + rapid water quenching (10–15°C) |
| PP Core-Reinforced | 20% CaCO₃ filler | High-torque extrusion (backpressure 25 MPa) |
II. Multi-Color Coextrusion & Dynamic Color Switching
Digital Pneumatic Material Switching
- 3/5-Color Gradients: Pneumatic valves control masterbatch ratio (±0.5% accuracy) → 3-color switch in 10 min (residual <0.1%), enabling complex textures (e.g., dream rattan).
- Spiral Winding: Multi-head extrusion + planetary gear drive → helical wrapping for 3D texture & ↑ weaving efficiency.
Color Uniformity Assurance
- Online IR Monitoring: Real-time melt color feedback → screw speed compensation (response 0.2 s).
- Nano-Masterbatch Premix: CaCO₃ carrier (0.1–0.5%) → color dispersion ↑ → ΔE<0.8 (SGS certified).
III. High-Efficiency Plasticization
Low-Temp High-Mixing Technology
- Zoned Heating: 6-segment electromagnetic heating (↓33% energy) → PVC temp 140–165°C (↓15–20°C vs. conventional).
- Two-Stage Vacuum Devolatilization: Vacuum -0.095 MPa → removes PVC volatiles (residual <0.01%).
Throughput & Efficiency Metrics
| Model | Max. Output | Line Speed | Energy Consumption |
|---|---|---|---|
| HPSJ-RA-01 | 55 kg/h | 60 m/min | 0.8 kWh/kg |
| Industry Standard | 45 kg/h | 40 m/min | 1.2 kWh/kg |
IV. Smart Control & Eco-Systems
Multi-Parameter Closed Loop
- PLC-HMI Integration: Melt pressure sensor + laser gauge + IR thermography → dynamically adjusts:
- Screw speed (11–18.5 kW motor stepless control)
- Haul-off sync (compensation ±0.02 mm)
- Cooling water flow (staged temp control).
- Unmanned Winding: Dual-position auto-spool change + 20 m buffer → continuous production.
Green Manufacturing
- Filter-Dust Collection: Modular dust capture → ↓75% PM2.5 in workshops.
- Closed Water Loop: Reuse rate >98% → national green factory pilot certification.
V. Applications & Process Optimization
| Product Type | Core Process | Technical Breakthrough | Peak Output |
|---|---|---|---|
| Tricolor Dream Rattan | Pneumatic color-switch + air cooling | Gradient accuracy ±0.5% | 55 kg/h |
| UV-Resistant Rattan | PE + 2% anti-aging agent + staged cooling | Weathering resistance >10 years (QUV test) | 50 kg/h |
| Core-Reinforced Rattan | PP/CaCO₃ coextrusion + magnetic tension | Core adhesion >15 N/mm² | 40 kg/h |
VI. Technical Barriers & Industry Trends
Current Advantages
- Multi-Color Efficiency: Color-switch speed ↑30% vs. Komax HELICAL → supports 5-color coextrusion.
- High Recyclate Blending: 30% recycled PP/PE blend → tensile strength retention >90% (≥18 MPa).
Future Development
- Bio-Based Materials: Corn-starch PE rattan (≥40% bio-content) → ↑50% degradability.
- Digital Twin Optimization: AI vision QC → 99.9% defect detection → “zero-defect smart manufacturing”.
Featured Content
Featured Content
