Automatic Vacuum Expandable Polystyrene (EPS) Shape Moulding Packing Machine

The Automatic Vacuum EPS Shape Moulding Packing Machine represents a cutting-edge innovation in the field of polystyrene product manufacturing. It is a highly sophisticated solution that has been meticulously engineered to deliver maximum production efficiency. With its revolutionary design concept, rugged and durable construction, and highly accurate control mechanisms, it has emerged as the top choice for contemporary packaging requirements.

Key Features

1. Unique Machine Structure

• Enhanced Frame Strength: The machine's back frame and moving frame have been substantially reinforced, featuring an integrated body and foot structure. This unique design not only endows the machine with outstanding durability but also imparts remarkable stability during operation. The seamless integration of the frame and machine feet effectively distributes stress and load, thereby significantly augmenting the overall structural integrity and strength of the machine.
• Durable Finish: A zinc spraying treatment has been applied to the frame, which serves as a highly effective protective layer. This treatment significantly enhances the frame's resistance to both corrosion and wear, thereby safeguarding the machine from the deleterious effects of environmental factors and the rigors of continuous operation. As a result, the machine's lifespan is considerably extended, ensuring a long-term and reliable performance.
• Tie Bar Design: The machine is equipped with opposite-direction tie bars, which have been ingeniously designed to simplify maintenance procedures. These tie bars exhibit excellent wear resistance properties, ensuring a prolonged service life. Moreover, self-lubricating copper tubes have been incorporated in place of traditional bushings. This innovation leads to a remarkable improvement in lubrication efficiency, reducing friction and wear between moving parts and further enhancing the overall operational smoothness and reliability of the machine.
• Stainless Steel Plates: The preventing and back mold plates are fabricated from high-quality stainless steel. This material selection is crucial as it effectively mitigates the occurrence of rust and wear, thereby maintaining the precision of the molds over an extended period. The use of stainless steel plates not only ensures the dimensional accuracy of the molded products but also contributes to the overall quality and consistency of the final output.

2. Hydraulic Pressure System

• Enhanced Speed: The hydraulic system of this machine has been optimized to operate at a significantly higher speed of 250 mm/s, in contrast to the 180 mm/s of previous models. This enhanced speed translates directly into a reduction in cycle time, enabling a substantial boost in production efficiency. The faster operation of the hydraulic cylinders allows for more rapid mold opening, closing, and product ejection, thereby increasing the overall throughput of the machine.
• Safety Locking: During the steaming process, the hydraulic cylinders play a critical role in securely locking the molds. This safety feature is essential as it effectively prevents steam leakage, which could otherwise lead to product defects, energy wastage, and potential safety hazards. By ensuring a tight seal, the machine can maintain the required steam pressure and temperature within the mold cavity, facilitating the proper formation and curing of the polystyrene products.
• Simultaneous Operation: The ejecting and de-mold cylinders have been engineered to work in perfect harmony. They execute simultaneous gas blowing and product ejection operations, which is a key factor in minimizing cycle times. This synchronized action streamlines the de-molding process, enhancing the overall efficiency and productivity of the machine. By reducing the time required for each production cycle, the machine can produce a greater quantity of high-quality polystyrene products within a given time frame.

3. Advanced Steam System

• Precise Control: The machine is equipped with a Fang-Yuan patented PID system, which represents a significant technological advancement in steam pressure control. This system is capable of maintaining an extremely accurate steam pressure within the range of 0.10 - 0.15 MPa, with a remarkably tight tolerance of ±0.1 MPa. By precisely regulating the steam pressure, the heating time can be effectively reduced, leading to a substantial reduction in energy consumption, typically in the range of 25 - 30%. This not only results in significant cost savings but also contributes to a more sustainable and environmentally friendly production process.
• Touchscreen Control: The steam pressure and mold pressure can be conveniently adjusted via a user-friendly touchscreen interface. This intuitive control method allows operators to easily set and fine-tune the parameters according to the specific requirements of different production runs. The touchscreen interface provides real-time feedback and visual indicators, ensuring precise and hassle-free operation. It also simplifies the training process for new operators, enabling them to quickly become proficient in operating the machine.

4. Efficient Piping System

• Optimized Design: The piping system of the machine has been carefully designed to maximize efficiency. Large pipelines and valves have been strategically positioned in close proximity to the mold. This layout minimizes the distance that steam and other fluids need to travel, thereby reducing energy waste associated with fluid transport. Additionally, the close proximity of the components enhances the operational speed of the machine, as the response time for steam injection and fluid transfer is significantly reduced. This optimized piping design contributes to the overall high-performance and energy-efficient operation of the machine.

5. Vacuum System

• Vertical Vacuum System: The machine features a vertical vacuum system that is equipped with a 4 - 6” large drain pipeline and an extended condensation drainpipe. This configuration is designed to enhance the efficiency of steam condensation and removal. The large drain pipeline allows for rapid evacuation of condensate, while the extended condensation drainpipe provides additional surface area for heat exchange, facilitating more efficient steam condensation.
• Water Content Control: Vacuum cooling has been adopted as the primary cooling method, with water cooling being used only for a limited duration of 8 - 12 seconds. This approach is highly effective in controlling the water content of the final product, ensuring that it remains at or below 10%. By minimizing the water content, the quality and dimensional stability of the polystyrene products are significantly improved. Additionally, the reduced water content also contributes to a shorter drying time and a more efficient production process.
• Convenient Maintenance: The spray header of the vacuum system has been designed with ease of replacement and maintenance in mind. This feature allows for quick and hassle-free servicing of the spray system, minimizing downtime and ensuring the continuous operation of the machine. The modular design of the spray header enables easy access and replacement of individual components, reducing the complexity and cost of maintenance.

6. Intelligent Control System

• Comprehensive Control: The machine is equipped with a highly intelligent control system that enables remote adjustments for all pressure-related operations. This includes the precise control of cross steaming, main steaming, and filling processes. The control system also features tailored programs for different foaming areas, allowing for customized production according to specific product requirements. Additionally, built-in self-protection and alarm systems are incorporated to ensure the safe and reliable operation of the machine. These systems continuously monitor various parameters and automatically detect and alert operators in the event of any 异常情况，preventing potential damage to the machine and ensuring the quality of the products.
• Premium Components: To guarantee the stability and reliability of the machine's operation, it is equipped with top-of-the-line international-brand electronic, hydraulic, and valve components. These components are renowned for their high quality, durability, and advanced technological features. The use of such premium components not only ensures the smooth and efficient operation of the machine but also minimizes the risk of breakdowns and maintenance issues, thereby providing a long-term and dependable solution for polystyrene product manufacturing.

Why Choose This EPS Shape Moulding Machine?

This state-of-the-art EPS Shape Moulding Machine combines the advantages of high-speed operation, excellent energy efficiency, and a rugged and durable construction with advanced automation capabilities. Its highly precise control systems and robust design make it the ideal solution for achieving efficient and high-quality EPS packaging production. Whether it is for large-scale industrial manufacturing or for meeting the demanding requirements of customized packaging, this machine offers the reliability, performance, and flexibility needed to stay competitive in today's market.

Related Question and Answer

Question 1: How does the integrated body and foot structure of the machine enhance its durability and stability?
Answer: The integrated body and foot structure distributes stress and load more evenly throughout the machine. It reduces the concentration of forces at specific points, which helps prevent structural damage and deformation. This enhanced durability allows the machine to withstand the rigors of continuous operation over an extended period. The stability is improved as the integrated design minimizes vibrations and movements during the molding process, ensuring that the molds are precisely aligned and that the products are formed with consistent quality.

Question 2: What benefits does the self-lubricating copper tube in the tie bar design bring to the machine's operation?
Answer: The self-lubricating copper tube improves lubrication efficiency compared to traditional bushings. It ensures a continuous and smooth supply of lubricant between moving parts, reducing friction and wear. This leads to a longer service life for the tie bars and other associated components. It also minimizes the need for frequent manual lubrication, reducing maintenance time and costs. Additionally, the reduced friction contributes to more precise and stable movement of the molds, enhancing the overall quality of the molded products.

Question 3: How does the Fang-Yuan patented PID system in the steam system achieve energy savings?
Answer: The Fang-Yuan patented PID system precisely controls the steam pressure within a very narrow range (0.10 - 0.15 MPa with ±0.1 MPa tolerance). By accurately maintaining the required steam pressure, it avoids over-pressurization and unnecessary steam consumption. This optimized control reduces the heating time as the steam is used more efficiently. As a result, energy consumption is cut by 25 - 30% as the machine only uses the amount of steam necessary for the proper molding and curing of the polystyrene products, rather than wasting steam due to inaccurate pressure control.

Question 4: Why is vacuum cooling preferred over water cooling and how does it affect the final product?
Answer: Vacuum cooling is preferred because it is more efficient in removing heat and controlling the water content of the final product. It allows for rapid steam condensation and evacuation, reducing the overall cooling time. By limiting water cooling to 8 - 12 seconds and relying mainly on vacuum cooling, the water content of the product can be kept at or below 10%. This low water content improves the dimensional stability and quality of the polystyrene products. It also reduces the drying time required after production, enabling a more streamlined and efficient manufacturing process.

Question 5: How does the intelligent control system's tailored programs for different foaming areas benefit the production process?
Answer: The tailored programs for different foaming areas allow the machine to adapt to the specific requirements of various products. It enables precise control over the foaming process in different regions of the mold, ensuring that each part of the product is formed with the correct density and shape. This customization improves the quality and consistency of the final products. It also allows for more efficient production as the machine can be quickly adjusted to produce different types of polystyrene items without significant reconfiguration or downtime, enhancing overall productivity and flexibility in the manufacturing process.