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Views: 0 Author: Site Editor Publish Time: 2016-04-20 Origin: Site
In SPC flooring production, the uncertainty of manual operations is often the "invisible killer" of quality fluctuations—minor deviations in temperature control or tiny differences in raw material proportions can cause entire batches to suffer from uneven density or surface defects. However, through digital control and intelligent collaboration, the fully automatic SPC extruder significantly eliminates manual intervention from the production process, ensuring that the quality of every meter of flooring remains as consistent as "copy and paste," thus becoming the core guarantee for large-scale production.
From "Manual-Dominated" to "Machine Autonomous": Breakthroughs in Full-Process Automation
Traditional extruder production relies on the experience and judgment of operators. For example:
· Judging the mixing temperature of raw materials by hand feel, with possible errors of ±10°C;
· Adjusting screw speed by observing the color of the melt with the naked eye, which often leads to density fluctuations;
· Manually recording production data, which is prone to mistakes or omissions, affecting traceability.
Equipped with an intelligent batching system, it precisely controls the dosage of PVC resin, calcium carbonate, and additives through laser level sensors, with an error within ±0.5kg. In the mixing stage, infrared temperature measurement and automatic stirring speed adjustment are adopted to ensure that raw materials complete pre-plasticization within the optimal range of 120-130°C, avoiding "over-mixing" or "under-mixing" caused by manual judgment.
The barrel is equipped with 16-point temperature sensors and pressure transmitters, transmitting 30 sets of data to the central control system every second. When the melt pressure exceeds the set range (for example, suddenly rising from the normal range of 15-18MPa to 20MPa), the system will automatically reduce the screw speed and enhance cooling, pulling the parameters back to the standard value within 5 seconds. A laser thickness gauge at the die outlet monitors the thickness of the sheet in real time. When the deviation exceeds 0.05mm, it automatically fine-tunes the die lip opening to ensure that the thickness tolerance of each floor is ≤0.1mm.
The extruded sheets are conveyed to the cooling rack by an automatic traction machine, and the conveying speed is adjusted by the servo motor linked with PLC to perfectly match the extrusion rhythm, avoiding deformation caused by manual dragging. At the same time, production data (such as hourly output, temperature curve, and rejection rate) is automatically uploaded to the cloud system to generate traceable electronic reports without manual entry, with a data accuracy rate of 100%.
For downstream brands, the "consistency" of SPC flooring directly determines the installation effect and reputation—batch color differences may lead to customer returns, and uneven thickness will increase construction difficulty. Through stable quality output, the fully automatic extruder helps manufacturers:
· Reduce rework costs caused by quality problems (a certain enterprise saved 50,000 yuan in rework fees per month after upgrading);
· Obtain access to high-end markets (for example, exporting to the EU needs to meet the strict tolerance requirements of EN 14041 standard);
· Improve customer repurchase rate (stable quality increased the contract renewal rate from 65% to 92%).
As the market shifts from "competing on price" to "competing on quality," production consistency has become the core competitiveness of SPC enterprises. The value of the fully automatic SPC extruder lies not only in reducing the labor cost of 3-5 operators but also in converting every input of raw materials into qualified products and ensuring the stable delivery of every order by eliminating human errors.
If your factory is still troubled by batch quality fluctuations, it is worth thinking: when competitors' product qualification rate is stably at 99%, while your products have a 5% defect rate due to manual operations, the gap is not just in numbers—it is the ebb and flow of market share.
· Automation Level: Industry 4.0 standard (supporting remote monitoring/parameter adjustment)
· Applicable Raw Materials: PVC SG-5, calcium carbonate (maximum filling 70%)
· Output Range: 500-2500kg/h
· Data Storage: Supporting 180-day cloud traceability of production records
· Energy Consumption: 25% lower than traditional models (due to reduced downtime for debugging)
