EQUIPMENT AND MANUFACTURING FOAMS ALLOWS TO START SMALL BUSINESS WITH SMALL INVESTMENTS
Polyfoam (foamed polystyrene) today insulated most of the apartments and houses. It is used as a packaging material. It will serve as an ideal shumizolyator. As an effective insulation, always in demand in the market of building materials. At the core of the business idea is a small price of equipment and high demand for the finished product. To assess the investment interest in the business of the production of foam, you should analyze two indicators:
The difference between cost and market price.
Consumer interest in foam plastic in the building materials market.
Naturally, the cost of purchasing the necessary equipment and raw materials should be included in the cost. Inexpensive equipment for the production of foam can be purchased from $ 4650 (minimum grade) and up to $ 26,000 (production line with a capacity of 100 cubic meters per shift). Such prices attract small business to the equipment for the production of foamed polysitrol. But it is also important to consider the cost of raw materials.
The raw material used is polystyrene granules. They differ among themselves not only by price, but also by chemical indices. Domestic polystyrene is cheaper, but the foreign one is more qualitative, because of this it has an increased level of productivity (more than 10%). On average, the cost of such granules ranges from $ 2.3 per 1 kg.
SET OF EQUIPMENT AND TECHNOLOGY OF PRODUCTION OF FOAM
Equipment for the production of foam. The production line of polyfoam is completed with the following equipment and consumables:
Cutting foam blocks.
The main component of the foam are polystyrene granules. In appearance, they resemble translucent glass beads, the size of which varies in the aisles from 0.02 cm to 0.35 cm in diameter. Depending on the type of polystyrene, the appropriate granules are selected. For example, to obtain grade 50, polystyrene No. 1, the smallest polystyrene will be needed, and for grade 15, the 4th polystyrene number will be used.
Step by step description of the production of foam:
Churn. At this stage, steam is fed into the container with polystyrene granules loaded into it, from the steam generator. When exposed to steam, which enters the container under pressure, polystyrene granules begin to increase in volume. In about 4 minutes they increase in size up to 50 times. In this process is fully controlled. The operator controls the flow of steam, and when the granules reach the required size, turns off the steam generator. After that, the expanded polystyrene (foam) is unloaded from the container.
To dry At this stage, foamed polystyrene must be eliminated from excessive moisture. To do this, a constant shaking of the wet granules takes place on the dryer, while hot air is supplied to the bottom of the dryer. This process also takes about 4 minutes.
Give a lie down. Now, the dried granules are placed in the next tank. In this tank, foamed and dried polystyrene will be in a state of complete rest from 4 to 12 hours. Drying time depends on the brand of foam produced.
Formation. The prepared raw material takes its presentation, in which you and I see foam in retail outlets. To do this, the entire foamed polystyrene mass is placed in special forms of block type. In these forms and “bake” foam blocks. They are baked under the influence of high temperature and pressure. Sintering time of foam plates lasts from 6 to 12 minutes.
Exposure. Sintered blocks should be left to mature. It would seem that everything is ready for our foam plates to go on sale. But it is not. After the blocks are removed from the sintering molds, they need some more time to lie down. To do this, the sintered blocks are sorted and sent to the warehouse, where they must lie from 2 to 4 weeks. This is necessary in order for foam to evaporate all the excess moisture.
Cutting. Now you need to give a presentation. For this you need special equipment. In such an installation (machine), foam blocks, using string cutting, are divided into plates. Standard thickness of plates is 2,3,4,5 and 10 cm. On such equipment, you can cut foam blocks and to order, the thickness that is required by the customer.
Recycling industrial waste. We transform the production of foam plastic in non-waste production. As mentioned above, the production of foam blocks waste-free. It is justified by the fact that prunings obtained at the 6th stage of production will be recycled. And they are added to the production process at stage 4. Trimming is not necessary to split up, and you need to add them to the block form together with prepared granules in the ratio of 1 to 8. The structure of this foam will be similar to the homogeneous.