EPS block molding machine also called has two working modes: normal feeding and pressure feeding. The two modes can be switched according to the structure and form of the mold. Can choose automatic, semi-automatic and manual operation mode.
EPS foam shape molding machine Description
The EPS block molding machine is driven by hydraulic pressure and a fast/slow differential system to ensure precise time saving and stable operation for opening and closing the mold.
EPS foam shape molding machine has two working modes: normal feeding and pressure feeding. The two modes can be switched according to the structure and form of the mold. Can choose automatic, semi-automatic and manual operation mode.
Various heating methods can be selected according to the product form to ensure product quality. The vacuum negative pressure system can ensure low water content, fast forming, and short drying time (or no drying).
thing
unit
GPZ1412
GPZ1714
GPZ1816
Standard mold size
Mm
1400*1200
1700*1400
1800*1600
product size
Mm
1200*1000*380
1500*1200*380
2000*1400*380
Mold opening distance
Mm
210-1610
210-1610
210-1610
Steam consumption
Electricity/electricity
8-12
8-12
8-12
Steam inlet
Mm
DN100
DN100
DN100
Cooling water inlet
Mm
DN80
DN80
DN80
Outlet hole
Mm
DN125
DN150
DN150
Compressed air consumption
Kg/cycle
1.4
1.6
1.8
Vacuum pump
Cubic meter/minute
4.66
4.66
4.66
Installed power
kilowatt
17.2
17.2
17.2
Dimensions
Mm
4950*2300*5350
4950*2650*5550
4950*2750*5750
Machine weight
Ton
7.8
8.5
9
cycle
Second
50-110
60-120
60-130
By steam heating and air cooling, the eps foam bead becomes a large foam board. The PLC English touch screen is adopted to realize the fully automatic production of various shapes of foam boxes for feeding, heating, air cooling, mold opening, mold closing, and ejection.
● EPS Foam Shape Molding Machine adopts Japan, imported touch screen, full English display, intelligent graphical interface control, realizing man-machine dialogue.
● EPS Foam Shape Molding Machine can be fully automatic and semi-automatic.
● Taiwan AIRTCA hydraulic system runs smoothly, with low noise and large clamping force.
● The vacuum system speeds up the product forming speed, shortens the cooling time, and reduces the moisture content of the product.
● The optimized design is clear and generous, with high strength and high cost performance.
● This EPS Block Molding Machine can perform processes such as heating, cooling, feeding, stripping, etc., to adapt to different EPS products.
● Complete fault detection system and motor protection system to ensure the safe operation of equipment.
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3,
In the last few decades, the focus on Total Quality Management (TQM) philosophy has significantly gained attention among industry practitioners and academics. The emphasis is on the application of the TQM theories to manage and improve the various organisational aspects, so as to deliver a quality outcome i.e., a good or service to the end-user. Organisations use a multitude of TQM tools and techniques to continuously improve process outcomes [ 1 ]. TQM has evolved in different quality domains from the substantial contributions of Shewhart (Statistical Quality Control), Deming (Process Control Quality), Juran (Quality Management), Feigenbaum (Total Quality Control), Crosby (Quality Cost), Ishikawa (Preventive Quality), and Taguchi (Design Quality) [ 2 4 ]. Moreover, different TQM methodologies have been successfully implemented in various industrial settings across distinct organisational levels [ 5 6 ]. With the increased material, energy, and operational costs, organisations continuously look for opportunities to optimise their operations to gain competitive advantage [ 7 ]. Based on Taguchi’s methodology, this paper describes a case study in an industrial setting, which is facing challenges in producing high-quality products that are sensitive to various causes of variation.
In the building and construction industry, expanded polystyrene (EPS) is extensively used to produce pods and blocks for under floorings and insulation panels, which are the two essential components that are required in the buildings. A pod is a semi-hollow grid component, which resembles with a honeycomb, whereas a block is a solid module that is cut into sheets to produce insulation panels. Post February 2011 earthquakes in Christchurch (New Zealand), there has been an ongoing mass scale rebuild process in the city to redevelop the infrastructure for commercial and residential purposes. New materials, possessing earthquake resistant properties, are being produced and used in buildings to minimise the impact of any such natural calamity in future. As a result, there is a surge in the demand for new construction and building materials that can withstand earthquake shocks to reduce sufferings of the various affected community segments.
2) on EPS surface through a photocatalytic study. Kannan et al. [
In this paper, a pod-manufacturing process is considered in the EPS supply chain to study the impact of the various process parameters on the quality of the pod. The variation in the pod manufacturing process with regard to the response variable i.e., weight of the expanded beads forms the basis for this study. In general, EPS is also suitable for manufacturing various types of packaging material for consumer goods, including foodstuff, horticulture, and electronics. EPS, which is a synthetic polymer made from the styrene monomer, is extremely light, durable, and resistant to moisture. On the daily basis, a considerable amount of EPS based materials are produced, a portion of which results in waste. This leads to the increase in carbon footprint, which eventually ends up affecting the environment. Furthermore, variation in the manufacturing practices or non-compliance to the standards and procedures might lead to increased processing time and cost, which might affect the sustainability aspects across the EPS chain. EPS has been the focus of work for academics for long. Horvath [ 8 ] provided useful information regarding the various mechanical, physical, and thermal properties of the EPS. Chen and Liu [ 9 ] investigated the properties of reinforced concrete structures with respect to EPS and styrene-butadine rubber by considering two types of spherical EPS beads to test the strength of polymer-cement ratios. Whereas, Magalhães and Lago [ 10 ] studied the impact of Titanium dioxide (TiO) on EPS surface through a photocatalytic study. Kannan et al. [ 11 ] addressed the issues that surround the decomposition of EPS by considering heating rate and gaseous environment as the parameters. The studies that were conducted by Varnagiris et al. [ 12 ] and Shirazi et al. [ 13 ] analysed the moisture adsorption and resistance aspects of coated EPS foam beads under mechanical stresses, such as shear and compressive stresses. Furthermore, EPS has been the topic of interest for researchers in various other applications areas. For instance, various aspects of EPS have been explored in different applications such as nano-manufacturing [ 14 15 ], construction [ 16 17 ], composite materials [ 18 19 ], waste [ 20 21 ], and recycling [ 22 ].
In view of the utility of the EPS pods, especially in the construction industry, it is of utmost important to ensure the quality of the final deliverable. It has been observed from the literature that information pertaining to the systematic experimental investigation of the effect of the various pod production process parameters on the quality of pods is lacking. Keeping this in view, an attempt has been made in this paper to explore effect of the critical pod production process parameters on the pod quality that is measured in terms of weight of the expanded beads. Further, this paper also aims at determining the optimal combination of the process parameters while using Taguchi’s design of experiment. If the pod production process is operated at optimum levels of the process parameters then it would produce high quality pods and helps to mitigate the ripple effects of poor quality down the chain. The pod production process was observed and experiments were conducted to study the effects of critical factors in producing pods at one of the major New Zealand based EPS facilities. The study that is presented in this paper is expected to provide useful information to the stakeholders who are associated with EPS pod production.
Polystyrene is used across all industries, from toys and parts of consumer goods to insulation and packaging materials. It is also the ingredient for the synthesis of new plastics. Polystyrene is used in its solid, film, and foam form, forms the polymer matrix in composites, and works as the basis for co-polymerized plastics.
Solid or rigid form: this polystyrene type is transparent, rigid, brittle, and moderately strong in its unmodified state.
Foam form: the most notable use of polystyrene is in a foam form, also known as Expanded Polystyrene (EPS).
Film Form: films made from polystyrene are transparent, durable, and printable.
Composites: Polystyrene is used as a base polymer matrix to fabricate fiber reinforced composites.
Co-polymerized Polystyrene: polystyrene is usually combined with other compounds to synthesize plastics with unique properties. These include ABS, SBR, SAN, and HIPS.
Polystyrene is used in applications from appliances to medical products to automotive parts. Appliances use polystyrene foam as insulation, while its rigid form is used for housings and casings. Electronics also use this material’s rigid form for housings and casings. Polystyrene is also food safe, so it’s used in food service applications as rigid silverware and containers for food and drinks, as well as polystyrene film as part of meat and takeout packaging. The medical field also uses this material in test tubes and Petri dishes. Construction also benefits from this material as polystyrene foam is used as insulation. Another industry that uses polystyrene is the automotive sector, which uses pure polystyrene for children’s protective seats and composites of this material for automotive bodies and components.
Plates and cups can be made from polystyrene, as can sound dampening foam and protective lamination over posters and other products. Wind turbines and corrosion-resistant pipes can also be made of polystyrene. Its co polymerized forms of ABS, SBR, SAN, and HIPS can be used for applications from 3D printed prototypes to optical fibers rubber gaskets to automotive gas tanks.
The advantages of polystyrene plastic injection molding are low shrinkage, moldability, and the flexibility to be used in blended and foam form. Polystyrene, like all thermoplastics, is reusable and easily molded. It also features low shrinkage during the plastic injection molding process. Usually, polystyrene shrinks less than 0.5%, which is low compared to other injection molded plastics. This property makes it possible to capture intricate design details of parts. Besides this, polystyrene features less warpage and produces uniform-shaped parts where designers can make accurate dimension predictions of finished parts.
Polystyrene foam can also be used in an injection molding process called structural foam molding to create rigid but light structures for different applications. Co-polymerized polystyrene is injection molded as well to produce parts with improved mechanical properties.
The disadvantages of the polystyrene plastic injection molding process are low melt flow index, high melting point, and a short temperature range. Polystyrene melts at a relatively high melting temperature of 210 ºC to 250 ºC, requiring higher energy demand to perform the injection molding process. Polystyrene also has a low melt flow index, with a typical value of 12 to 16 g/10min, which is the ease of flow of molten plastics during the injection molding process, measured in grams of plastic flow in 10 minutes.
The temperature range at which polystyrene begins to soften and melt is relatively short, and the process must be carefully monitored and designed accordingly. Unmodified polystyrene is also brittle, making parts prone to failure during the ejection of parts from the mold. There must be careful ejection pin design to ensure the parts can withstand the flexural stress endured during ejection. Polystyrene co-polymerization with compounds like rubber or butadiene is also often used to improve the material’s impact strength and make the plastic less brittle.
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