Polyfoam is used in almost all industries, in particular:
- in the production of building materials for insulation, sound insulation, decorative elements;
- in the manufacture of packaging materials;
- in medicine for the manufacture of thermally stabilizing containers;
- in shipbuilding of small vessels to fill special compartments to ensure unsinkability.
The production of foam products is a fairly simple process, the technology does not require specialized education, although it is certainly welcome. Manufacturers of equipment make turnkey mini-factories - this means that it is completely ready for work, they also provide a full description of the technological process, with all proportions.
Styrofoam Production
In Russia, there are not many factories producing foam products, and foreign products, which have a high cost, are quite popular. All this speaks of the great competitive advantages of this business, since the demand in this industry exceeds supply, and, therefore, the owner can receive super-profits.
The components of the mini-factory, their technical characteristics
Today you can buy equipment of domestic production, Chinese and European. According to the price category, Russian and Chinese are at the same level, but it is also necessary to take into account the cost of delivery and maintenance of the equipment, because often you may have questions about operation or call a specialist-adjuster, and it is easier to do this with a Russian company.
The AVIS-GROUP enterprise offers a mini-factory for the production of foam products of the following configuration:
pre-foaming agent - is necessary for preliminary heat treatment of polystyrene foam granules up to a density of 10 to 50 kg / m 3. Specifications:
- power - 2 kW;
- productivity - up to 200 kg / h;
- hopper volume - up to 60 l;
- dimensions - 220 * 900 * 1380 mm;
- weight - 240 kg;
- hopper for drying foam granules - thanks to this process, pressure stabilizes in the mass, a significant part of the moisture evaporates.
Specifications:
- productivity - 25 m 3 / h;
- case material - galvanized steel;
- dimensions - 500 * 1350 * 2000 mm;
- automatic block form - necessary for molding a foam sheet. The molding process is accompanied by cooling the mass using vacuum. Specifications:
- productivity - up to 18 m 3;
- the time of one cycle is 5 minutes;
- dimensions of the finished block - 640 * 1040 * 2040 mm;
- dimensions - 1500 * 750 * 2300 mm;
- Block-type automatic vacuum installation - necessary to remove excess air in the formed sheet, with its help the molding process is accelerated.
Specifications:
- power - 7.5 kW / h;
- productivity - up to 3 m 3 / min;
- receiver volume - 2.8m 3;
- a machine for cutting foam into sheets and various products of the required size. Specifications:
- productivity - up to 7 m 3 / h;
- minimum sheet thickness - 20 mm;
- dimensions - 1500 * Ф1300 * 4500 mm;
- packaging installation - wraps the finished product with PVC film.
Specifications:
- power - 1.5 kW;
- productivity - up to 60 m 3 / h;
- dimensions of the resting blocks - 600 * 1000 * 1000 mm;
waste shredder - necessary for crushing scraps after cutting finished sheets. This process is necessary for the organization of non-waste production, since the waste can be reused by adding to the granules, but not more than 5%.
Specifications:
- power - 7 kW;
- productivity - up to 5 m 3 / h;
- dimensions - 830 * 800 * 1300 mm.
Such a plant will cost 2,500,000 rubles.
What is needed for production and where to buy raw materials
The basis of production is polystyrene granules - PSV-S. They are obtained by polymerization of styrene, the surface is treated with substances that prevent the accumulation of electrostatic charges, which greatly facilitates storage and transportation. The following companies produce polymer raw materials in Russia:
- Gazprom Neftekhim Salavat;
- Nizhnekamskkhim;
- The alphabet of polymers;
- Plastprom.
The cost of domestic raw materials is from 56 rubles per 25 kg.
Imported raw materials from Chinese and European manufacturers will cost twice as much, but are of higher quality. When organizing production, it must be borne in mind that polystyrene granules should be stored at a temperature not lower than +18 ° C and humidity not more than 70%. Violation of storage conditions will directly affect the manufacturing process of the foam.
In addition to granules, various chemical components can be added to the foam composition, which will additionally provide resistance to burning. These are various chlorine and bromine-containing substances, but their amount should not be more than 5% of the total mass of the loaded granules.
Foam manufacturing technology
The manufacturing process involves several stages:
Profitability calculation of a foam mini-factory
To calculate profit, the following data is required:
- the cost of raw materials - 56 rubles per 25 kg;
- the production of polystyrene from polystyrene granules - 1: 1 - non-waste production;
- raw material consumption - 52 m 3 per shift (8 hours), 1248 - per month (24 working days);
- productivity - 12 kg / m 3 one sheet, 624 kg a day, 14976 kg a month;
- at this capacity, 25 packs of granules per day or 600 packs per month will be required;
- prime cost of 1 m 3 - 25 (packages) * 56 rubles / 52 m 3 (daily output) \u003d 26.92 rubles;
- the cost of a foam sheet weighing 12 kg / m 3 - 1150 rubles;
- profit from 1 m 3 of the finished product - 1150 - 26.92 \u003d 1123.08 rubles;
- profit from daily production volume - 58,400, 00 rubles;
- monthly income - 58,400 * 24 \u003d 1,401,600 rubles;
- salary, taxes and social contributions, utility bills and other expenses should be deducted from income — this is about 40%, that is, the business owner will have 840,960 rubles of net profit every month.
A mini-factory with technical characteristics that will ensure such productivity costs 2,500,000 rubles. With a stable monthly profit, which is ensured by an established system of marketing of finished products, the payback period may come in the first six months of the plant. Of course, these are only preliminary calculations, it is clear that it takes time to establish sales and stable production, but with the right organization you can get a net profit after the first year of work.
Video: Polyfoam production in the Urals
Expanded polystyrene production is a profitable business with an average threshold of entry. Expanded polystyrene is widely used in various fields - in construction, in the food industry, in the automotive industry.
This article will examine in detail both the units for the manufacture of conventional polystyrene foam and the equipment for the production of extruded polystyrene foam, you will learn what elements the production line consists of, and the main aspects of the manufacturing technology of this material.
1 Polystyrene foam manufacturing technology
The technology for the production of expanded polystyrene is rather unpretentious, and can be implemented even with the necessary minimum production equipment.
However, an important factor is the strong dependence of the quality of the final product on meeting all the requirements of the technology, since even the slightest drying of polystyrene foam, or, conversely, an attempt to cut insufficiently dried, raw material, can cause rejection of the entire batch of products (even if it is).
In general, the technology for manufacturing polystyrene foam consists of several successive stages.
At the first stage, the raw materials from which polystyrene foam (polystyrene foam) is made - expandable polystyrene (PSV) granules are loaded into the container of the pre-foamer with your own hands or using automated equipment.
Pellets preheat granules, as a result of which they inflate, increase in volume, and turn into hollow balls filled with air.
Foaming can be performed both once or several times. When re-foaming, the process is completely repeated - the raw materials with your own hands (or automatically) are re-immersed in the pre-foamer, warmed up, and increased. Re-foaming is used when it is necessary to obtain polystyrene foam having a minimum density.
The strength characteristics and weight depend on the density of polystyrene foam. In some cases, for the insulation of facades and similar load-bearing structures, high-density polystyrene foam is required, however, as a rule, due to its lower cost, low-density polystyrene foam is in great demand.
Material density is measured in kilograms per cubic meter. Strength is sometimes called actual weight. For example, polystyrene foam having an actual weight of 25 kilograms has a density of 25 kg / m³. This is much better than with.
Polystyrene raw materials, which are foamed once, guarantee the final density of polystyrene foam in the region of 12 kg / m³. The more foaming processes have been completed, the lower the actual weight of the product.
As a rule, the maximum number of foaming processes per one batch of raw materials is 2, since multiple due to multiple foaming greatly deteriorates the strength of the final product.
At the second production stage, foamed polystyrene enters the holding chamber, where it is aged for 24 hours. This process is necessary in order to stabilize the pressure inside the granules filled with air.
With each repeated foaming process, the aging process must be repeated. To create expanded polystyrene with a density of up to 12 kg / m³, the raw material is subject to several repeated cycles of foaming and aging.
After the raw materials have aged for the required amount of time, foam blocks are formed from the semi-finished product. This happens in a block form, inside of which the granules are processed by pressure-fed steam.
After the block is formed, the polystyrene is aged again for 24 hours - this is necessary so that moisture is removed from the polystyrene, since when cutting a wet block, the edges of the product will be torn and uneven, after which it gets on the cutting line, where the blocks are cut into plates of the required sizes and thickness.
2 Production equipment
Polystyrene foam production line includes the following elements:
- The site of storage and verification of raw materials;
- Foaming unit;
- Container for aging;
- Unit for forming blocks;
- The unit for cutting foam on;
- Land for storage of the finished product;
- Waste treatment plant.
2.1 Storage and inspection of raw materials
It is important that the polystyrene raw materials used for the production of expanded polystyrene meet all quality standards, since the characteristics of the finished expanded polystyrene strongly depend on it.
As a rule, the main domestic and foreign manufacturers for the production of expanded polystyrene use raw materials from the following companies:
- Xingda (China);
- Loyal Chemical Corporation (China);
- BASF (Germany).
Technological requirements allow the reuse of waste (recycled polystyrene boards). The amount of recycled materials should not exceed 10% of the weight of the final product.
Bags with polystyrene are unloaded by electric car, or, in the case of small packaging, with their own hands. Raw materials should not be stored for more than three months after the date of its production. The temperature storage mode of the foam at - from 10 to 15 degrees.
2.2 Foaming machine
This production line consists of a pre-foaming agent (usually of a cyclic type), a block for drying polystyrene foam granules, a pneumatic conveyor, and a control element.
Do-it-yourself polystyrene is discharged from the bags into the pre-foamer, into which hot steam (at a temperature of about 95-100 degrees) is supplied under pressure, under the influence of which primary foaming of the raw material occurs.
The process is controlled by computer equipment, which, when polystyrene reaches the specified volume, stops the steam supply, after which the semi-finished product enters the drying unit.
2.3 Container for aging
The granules from which excess moisture has been taken are transported to an aging container. In the container through conditioning, the set humidity and temperature and air humidity are constantly maintained.
At temperatures ranging from 16 to 25 degrees, the granules are aged for about 12 hours. During this time, the hollow foam granules are filled with air.
The technology of repeated aging, which is carried out in the case of secondary foaming, is similar to the method described above, and is carried out using the same equipment.
It is the volume of the container that to a greater extent determines the nominal productivity of the production line, so the number and size of bins must be carefully calculated based on the desired production volume.
2.4 Assembly for the formation of polystyrene blocks
From the container for aging, the granules of expanded polystyrene by pneumatic transport are fed into the intermediate chamber, which is equipped with a filling sensor.
Upon receipt of the required number of granules, the raw material is transported to the forming unit. A block mold is an airtight container that, after filling with granules, closes. Through the supply valve, hot steam is supplied to the block mold.
In the process of heat treatment under pressure, secondary foaming of the granules takes place, which expand, and when the desired temperature is reached, they are sintered into a monolithic block of expanded polystyrene.
The formed polystyrene foam is cooled in the same unit by pumping air from the chamber with a vacuum pump. To stabilize the internal air pressure in the polystyrene granules, the block is maintained at room temperature throughout the day.
2.5 Assembly for cutting polystyrene foam
After the required time has passed, the polystyrene block falls onto the cutting unit. The cutting line is an integrated equipment that is capable of cutting, both in horizontal and vertical plane.
This equipment has two operating modes - automatic mode for implementing a given program, and do-it-yourself mode. As a rule, the whole process takes place automatically.
The cutting element of the equipment is incandescent strings made of refractory steel, which are able to quickly and efficiently form foam sheets of the required shapes and sizes.
The electronic control system of the installation makes it possible to set up the temperature of the strings, the speed of their movement, and the size of the final product.
2.6 Waste treatment plant
Polystyrene foam materials damaged during the production process are not disposed of, but are subject to recycling. Processing of polystyrene foam is carried out in the unit, inside of which crushing hammers rotate, which crush the foam plates into separate granules.
The raw materials obtained during processing through pneumatic conveying are fed to a storage hopper, from which the granules fall into the block form in an amount not exceeding 10% of the weight of the primary raw materials used for production.
2.7 Production of extruded PPP
The difference in the production line for the production of extruded polystyrene foam, in comparison with the above technology for the production of conventional polystyrene foam, is the availability of an extruder.
Extruder - equipment for the production of extruded polystyrene foam having forming dies through which the polystyrene melt is pushed.
The extrusion head gives the polystyrene foam the required structure, as a result of which monolithic products are obtained that have closed cells with a diameter of 0.1 mm that are superior to conventional polystyrene foam in terms of hydrophobicity and vapor permeability.
This technology provides a different approach to foaming of raw materials, which occurs due to the mixing of granules with a foaming agent in a nitrogen atmosphere.
2.8 Foam production technology (video)
In this material:
The area of \u200b\u200buse of foam is very wide. The limits of operation are not limited to packaging containers, as most citizens think. Polyfoam is used in large quantities in the construction and decoration sectors, medicine, various manufacturing, etc. Hence, it follows the logical conclusion that the production of foam plastic is a profitable business project that even young entrepreneurs can realize. A prerequisite for a successful start is the business plan of the company for the production of foam, because without thoughtful phased measures for the organization of the project and financial calculations, the idea may crash already at the preparation stage.
Description of a business idea, its relevance and advantages
The goal of the project is the organization of a foam plastic business in a city with a population of 500,000 or more.
Type of project - own mini-factory with an area of \u200b\u200b200 square meters. m
Means - loan or sponsor attraction. The minimum budget is 2.5 million rubles.
Payback - from 1 year.
The essence of the business idea is simple - investing in the organization of a mini-plant for the production of foam, the purchase of raw materials and the sale of the finished product through wholesale chains.
The relevance of the business is simply explained, polystyrene is used in areas such as:
- metallurgical industry - the creation of insulated pipes and other metal structures requiring thermal insulation;
- tailoring - the use of polystyrene as a heater;
- medicine - the manufacture of containers for various needs, including the transportation and storage of medicines;
- architecture - making layouts;
- construction - the use of polystyrene as a heater and soundproofing material;
- logistics, trade - packaging material;
- other areas of production - the manufacture of furniture, disposable tableware, etc.
Despite the fact that in Russia there are several large factories for the production of foam, the relevance of small and medium-sized businesses of regional importance in this area does not cease to be relevant.
Project Advantages:
- Demand for products - polystyrene, in fact, is considered a consumable used for packaging and insulation. The wide demand is explained by the cheapness and mass use for various needs, which cannot be said about other materials with similar characteristics.
- Ease of production - modern equipment allows you to easily produce the required amount of products of any shape and quantity, depending on the wishes of the customer.
- Ecological - foam is made from environmentally friendly materials, which cannot be said about the chemical compounds of alternative products with similar characteristics.
Reference. The main advantage of the foam manufacturing business is the minimal cost of raw materials at a high margin on the final product. This results in a high income and quick payback of the project.
Foam Production Technology
Foam manufacturing is a fully automatic process that requires only the control of the machine operator.
The work process is as follows:
- Loading of raw materials - polystyrene granules are used.
- Activation of pre-foamer - the device delivers steam to achieve the desired volume with granules.
- Drying - granules are moved to a special compartment for complete drying.
- Curing - after drying, the raw materials must be cured within 12 hours.
- Creating a form - granules are moved to a hopper, where they are exposed to a vacuum, which creates a given shape.
- Unloading blocks - the finished foam is fed to the platform.
- Cutting - products are cut according to the specified dimensions.
Reference. Cut off parts of the foam are not discarded, but reused, so we can safely say that this is a waste-free production. The ratio of raw materials and finished foam for the manufacture of new products is 8: 1, respectively.
Raw materials
For the manufacture of polystyrene, polystyrene granules are used. The most popular brand is PSB-S 25F, which has a long shelf life, aging period and the quality of the final product, which is optimally suitable for most uses.
Other brands of polystyrene:
- PSB-S15;
- PSB-S25;
- PSB-S50.
The cost of 1 kg of polystyrene ranges from 50–70 rubles, which depends on the supplier (China or Russia), as well as on the brand of raw materials. The production of 1 cubic meter of polystyrene requires 15 kg of polystyrene. It is easy to calculate the cost of production - 15 * 70 \u003d 1,050 rubles.
In retail, the cost of polystyrene is from 300 rubles per sheet or 1,500 per package, which also depends on the thickness of the material. Again, it is easy to calculate the margin on the product and the payback period of the entire project in the presence of regular customers.
Market analysis: target audience, competition and risks
There are several ways to analyze the foam manufacturers market:
- search for information on the Internet;
- visiting large construction supermarkets of the city and obtaining information about the foam manufacturer;
- combination of two methods.
As a rule, more than 80% of entrepreneurs involved in the sale of building materials purchase finished products from suppliers. Hence - a high margin on goods, which includes the inherent costs of transportation, inflation, wages and much more. Such entrepreneurs cannot be considered competitors, although in the end they sell the same product.
It is necessary to identify the direct manufacturers of foam in the region, to determine their level in business (term of work, scale of activity, price segment) and compare with your own indicators. If possible, it is necessary to set the price of products not higher than competitors, and best of all, 3-4% lower.
Target audience of the project:
- construction companies;
- metallurgy industry;
- outdoor advertising installation business;
- manufacturing enterprises of various kinds;
- logistics related companies;
- businessmen owning catering points;
- shops, supermarkets, shopping centers.
Depending on the scale of the project, a businessman can collaborate with either one intermediary or several at the same time, fulfilling orders for the production of polystyrene foam for various fields of activity.
Possible business risks:
- Low-quality raw materials - the problem is solved by changing the supplier, as well as constant monitoring of product quality.
- Failure or premature wear of equipment - the risk is typical for used equipment, as well as in the absence of a guarantee from the seller.
- The human factor - violation of the foam production technology directly depends on the employees of the enterprise, therefore, in order to exclude any emergency situations, it is necessary to carefully select personnel, conduct training and periodic tests to know your responsibilities.
- Competition is a serious risk, especially if a competitor appears after the start of the enterprise. In this case, the entrepreneur needs to thoroughly review the financial plan of the business project, analyze the possibility of lowering the price, as well as launch an advertising campaign and form new offers on the market.
- Financial crisis in the country and the world - the solution to the problem is to regularly monitor the state of the economy in the country, the exchange rate and other nuances, including the political situation, which can directly or indirectly affect business.
Reference: 99% of all existing and potential risks are absolutely solvable subject to the business plan of the project, market analysis and competition both in the region of work and in the country as a whole.
Establishing a Styrofoam Business
Activity Registration
Foam production involves work in the status of IP or LLC. The choice between the two forms depends on the entrepreneur and the scale of the business. For example, for a mini-factory with an area of \u200b\u200b200 square meters. m, IP status is quite suitable, but at the same time, some problems with the sale of products may arise. Large companies basically do not work with private entrepreneurs, but in fact small businesses have multi-million dollar contracts "too tough" due to the limited budget of the project.
A legal entity (LLC) is optimally suited for the operation of a larger enterprise, which in the long term is aimed at reaching customers not only in the region where it is located, but also in neighboring regions of the Russian Federation.
The procedure for registering entrepreneurial activity in both cases is almost the same - collecting documents, submitting papers to the tax service, waiting for a decision. Certificate of entrepreneurial activity is issued within 5 days.
OKVED code - 25.21 (production of plastic products).
Taxation system - USN or UTII.
Production room
The optimal area for the foam production workshop is 100 square meters. m. In this case, it is worth considering the administrative part of the premises (up to 25 sq. m) and the warehouse (40-60 sq. m). As a result, the entrepreneur needs to rent a building of at least 200 square meters. m
Room Requirements:
- lack of moisture;
- the absence of rodents and other pests (appropriate processing is carried out before the start of production);
- a small remoteness of the enterprise from the urban infrastructure - if possible, you need to rent a room in the city, but location is allowed up to 5-10 km from the village;
- the presence of a convenient entrance for freight transport, including multi-ton trucks;
- the availability of nearby municipal transport links for the convenience of staff.
Search for suppliers of raw materials
Polystyrene in Russia is produced and supplied by several large factories, as well as intermediary firms. Exact addresses and contacts can be found on the Internet, as well as study reviews about each supplier and supplied product.
An alternative is to order raw materials from China. Today this is the most affordable option, and Chinese polystyrene is no different from domestic, but it is cheaper. As always, an entrepreneur needs to choose.
Equipment purchase
Technical equipment of the mini-foam manufacturing plant can be purchased both as a set and separately. For the standard type workshop, the products of which are foam sheets of various thicknesses and shapes, you will need:
- pre-blowing agent;
- hopper for receiving raw materials;
- block compartment;
- tables for cutting products;
- steam supply devices;
- unused polystyrene shredders;
- vacuum device;
- system control panel;
- additional equipment for mounting the machine and equipping it with individual blocks.
Staff
For a mini-plant for the production of polystyrene with the amount of equipment 1-2 units will require at least 4 people maintenance staff. Provided that the work will be carried out in 2 shifts, the number of workers increases to 8 people.
Minimum staff:
- handyman - 8 people;
- technologist - 1 person;
- accountant - 1 person;
- cleaner - 2 people;
- the watchman - 3 people.
In the future, it makes sense to purchase trucks and hire 2-3 drivers to deliver products to the customer.
Finding sales channels for finished products
There are several ways to implement polystyrene:
- wholesale trade with non-regular customers;
- retail through its own network;
- custom foam production.
Given that more than 75% of the target audience of a business is a construction industry, you need to be oriented in this direction. A broad advertising campaign will help in finding customers:
- videos on TV and radio;
- own site;
- outdoor advertising in the city and the suburbs;
- advertising in building catalogs;
- leaflets, booklets in construction stores;
- contacting construction companies.
Lower prices, the availability of favorable offers and high quality products will quickly find customers for the long term.
Financial calculations
Investments to start production
Initial investments (in rubles):
- 150 000 - conclusion of a lease of premises;
- 200 000 - repair and preparation of the building for work;
- 1,000,000 - purchase of equipment;
- 100 000 - arrangement of the office of the head, purchase of office furniture and equipment;
- 150 000 - purchase of raw materials;
- 15 000 - registration of entrepreneurial activity;
- 50,000 - advertising;
- 50,000 - market analysis and search for distribution channels.
Total: 1,715,000 rubles.
Current expenses
First month spending:
- 150 000 - rental of premises;
- 400 000 - salary (15 people);
- 40,000 - utilities;
- 100,000 - reserve fund.
Total: 690,000 rubles.
Income and profit calculation
The income of the foam manufacturing business consists of the volume of finished products and turnover. On average, a mini-factory produces 50 cubic meters of polystyrene per week. The cost of one cubic meter of products is 5,000 rubles. Profit per week - 250,000 rubles. Monthly income - 1 million rubles.
The net earnings of the enterprise are 200–250 thousand rubles, since it is necessary to deduct mandatory monthly expenses and taxes from 1 million rubles.
The payback period of the project will take 10-12 months.
When planning the opening of a foam manufacturing business, you need to remember not only the many positive aspects of the project, but also the potential risks. Perhaps the selected region or specific locality is not suitable for this kind of activity. It may be such that the funds taken on credit are not enough to complete the activities that have begun. There are many nuances, so a business plan is not just an important and necessary thing, but a direct solution to potential problems.
Order a business plan
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Plan
Styrofoam Production
About foam density
Where do they buy raw materials for production?
How to make polystyrene do-it-yourself
The main properties of the foam and its use
Styrofoamis a building material that consists of granular masses filled with gas. Today, foam has found wide application in the repair and construction industry. In particular, it is used as a sound - thermal insulation material for warming rooms and decorating internal walls. First foammade in europe in early twentieth century, later its industrial production was established. The finished product foam has excellent heat and sound insulation qualities, is resistant to temperature extremes and precipitation, does not emit any harmful substances, is not subject to decomposition by contact with microorganisms, environmentally friendly and non-toxic.
The range of application of this product is quite wide. Therefore, polystyrene quickly took the leading position in the building materials market. For example, foam slabs are used as heat-insulating and structural materials, in the field of construction, car and shipbuilding, aircraft manufacturing, and is also used as packaging and electrical insulating material
.
Polyfoam is a plastic, lightweight and easy to process material that is actively used by modern artists and designers in their art, animation and cinema. Using this material, you can create, for example, whole art objects of almost any shape and texture. In addition, various figures can be cut out of polystyrene foam, painted with paints, as a result, you will get an original toy or a fake of your own made of polystyrene foam, which will be a wonderful gift for relatives and friends for any occasion.
Styrofoam Production
Foam manufacturing steps:
1. Foaming polystyrene foam. The raw materials are placed in a special container where the material is treated with steam of low-boiling liquids.
As a result of foaming, the granules increase in volume from 20 to 50 times. After reaching the required level of granules, the steam flow stops, and the working material is removed from the tank. The process itself takes about 4 minutes.
The next step is drying. After foaming, the granules must be dried without excess moisture. Drying occurs under the influence of hot air, which comes from below, and continuous mechanical shaking. Drying time takes approximately 4 minutes.
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Aging. After drying, the material is sent to a special aging bin, respectively brand (15, 25, 35 and 50) where the aging process takes place. The entire procedure takes from 4 to 12 hours, depending on the size of the granules and t of the environment.
Sintering or formation of granules. All action takes place in a special block form, where foamed granules are fed. There, under high temperature and pressure, the granules sinter, take the form of a block. The process takes 6 to 12 minutes.
5. Block curing. Cooked blocks are sorted by brand and stored.
At first, the blocks can still give off the remaining moisture. The ripening period of the blocks takes from 12 to 30 days. 6. Cutting foam blocks. On a special foam machine, string cutting of foam blocks into plates of specified sizes is performed. Standard sizes are 20, 30, 40, 50 and 100 mm, other sizes are also possible determined by an individual order.
The final stage is the processing of residual material. The production of expanded polystyrene is waste-free, since all residual materials are crushed and added to pre-foamed raw materials in the proportions of 1: 8. At the output, you get a finished product - polystyrene - a modern, competitive insulation material, which is undoubtedly in demand in the consumer market of building materials .About the density of the foam The finished high-quality polystyrene foam has evenly spaced granules of equal size. If the material is of low quality type PSB, in this case a kink is formed at the contact points of balls of different sizes. Expanded polystyrene consists of thin-cell granules that are sintered between each other. Inside the polystyrene granules there are micropores, and there are voids between the granules.
The mechanical characteristics of the material depend on the density. The higher the density, the higher the strength and lower water absorption, hygroscopicity, vapor and air permeability. The density of the foam depends on kilograms per cubic meter. Usually, for foamed polymers this coefficient is not more than 50, but often varies from about 15 - 35.
For example, in ceramic brick, the average density is close to 1,800 kg per cubic meter. Of course, the higher the density of the material, the higher the rate of transfer of thermal energy between its particles. For comparison, the thermal conductivity of the same brick is 18-20 times higher than that of polystyrene. On the other hand, its mechanical strength depends on the density of the material, only in this case there is a direct relationship: the higher the density, the stronger the material. If the material is foamed repeatedly, then the density of the foam will decrease.
Perhaps for this reason, polystyrene is not used for the construction of load-bearing structures. As the name implies, foamed polymers are the result of hardened polymer foam. Most of the foam is air, which is contained in plastic cells. Therefore, such insulating properties and low density. Where do you buy raw materials for production? Currently, the production of raw materials is established around the world.
For example, such European manufacturers as BASF (Germany), Dvorex Sintez (Poland), Italian companies. Also, Korea, China, Turkey and Russia are a worthy producer of raw materials for the production of polystyrene foam. Moreover, according to the observations of other manufacturers, the quality of raw materials of a Chinese manufacturer has recently grown significantly, including the price / quality ratio. This fact prompts the European manufacturer to increase its competitiveness in the market, including the Ukrainian one.
The only drawback of cooperation with China is that delivery times can take up to 1.5 months. How to make polystyrene with your own handsPreparation of polystyrene at home is still not a safe process. Such a lesson is best done in special rooms, for example, in a workshop. And also prepare the necessary equipment in advance. All you need is polystyrene in the form of granules (they are quite small, so they are called beads) and special equipment. To make the foam yourself, you need a sufficient number of small granules of polystyrene. After that, these balls should swell and stick together.
This procedure is carried out by treating polystyrene granules with hot steam. As a result of such heating, the granules will begin to swell. After the granules are swollen, they will begin to emit gas, which will push them towards each other. At the next stage, the granules are interconnected, taking the form of the container in which they are located.
After the formed mass cools down, the foam can be considered ready. But it should be borne in mind that the quality of such a foam prepared with your own hands can be very mediocre. For the manufacture of high-quality polystyrene foam, it is necessary to use special equipment that will provide the entire production technology. And besides, experiments with such high temperatures in domestic conditions can harm not only health, but also the living room itself.
Expanded polystyrene blocks are empty boxes made of polystyrene foam. The size of such a block is 25 cm in height and width and 95 cm in length. It is worth remembering that although this process is simple, it belongs to the category of chemical and is accompanied by the release of volatile formaldehyde substances. Having reached a certain concentration, they can poison the manufacturers themselves, and everyone around. Scheme and equipment for the production of foam: 1 - raw materials; 2 - pre-foamer; 3 - aging hopper; 4 - block form; 5 - finished products; 6 - cutting foam blocks; 7 - pneumatic transport; 8 - steam receiver; 9 - compressor; 10 - steam generator; 11 - waste crusher. Do-it-yourself polystyrene foam manufacturing should be accompanied by very good ventilation. Therefore, in a city apartment, the production process cannot be launched. Need a separate room.
Best for this purpose, a hangar or a shed in a summer cottage, located away from living quarters. Also, you will need certain equipment that will have to be installed in this room. For the production of expanded polystyrene we need: granular polystyrene; steam generator; steam accumulator; compressor; hopper for aging granules; mold for forming blocks; pneumatic conveying; machine for cutting the finished product into slabs; control scales; measuring dishes. Dimensions of a block made of polystyrene. For the purchase of equipment you need spend about 500 thousand rubles.
Therefore, it is necessary to deal with the organization of the production of expanded polystyrene only when a sufficiently large volume of products is to be produced. For personal consumption, the manufacture of material is unprofitable. The production process is preceded by the purchase of raw materials. In most cases, polystyrene granules are sold in bags that weigh up to 25 kg. The main difference lies in the size, quality of the product and the country of origin.
In many respects, the last factor plays a decisive role on the quality and consumer properties of the finished product. The smaller the granule size of the material, the more solid and dense polystyrene foam can be obtained from them. In the process of manufacturing products with their own hands, it is necessary to take into account the duration of steam treatment and a number of other production technological nuances. In particular, you need to pay attention to the date of manufacture of the purchased raw materials. For granules that have been lying in the warehouse for a long period of time, the foaming process takes much longer.
Production technology
Some types of wall polystyrene foam blocks: Monolithic: 1 - ordinary, 2 - end. Collapsible: 3 - 200 mm wide, 4 - 300 mm wide. The process of manufacturing polystyrene foam itself is divided into several successive stages. To carry out this work with your own hands, you need: hot steam; electrical energy with a voltage of 380 V; cold water. First, the pellets are poured into the pre-foaming container with their own hands, where they are processed by hot steam with a temperature of 120-150ºС.
Steam is supplied to the system at pressures from 0.9 to 4.5 atmospheres. Its formation occurs in a steam generator that runs on solid or liquid fuel. To accumulate a sufficient amount of steam, a steam accumulator is used, where it is previously supplied from the steam generator. Already from it, steam enters the pre-foaming container. Under the influence of hot steam, the polystyrene granules begin to increase in volume. Careful observation is necessary to carry out this process.
Apply control weighing a certain amount of manufactured products. To carry out this work, a control scale and measuring utensils will be needed. After reaching the required density, the foam granules from the pre-foaming container are fed into a special drying bin. The material is dried using air heated to a temperature of 60-65ºС.
Then it is moved to another hopper designed for aging finished products. In this hopper, the product is stabilized. The granules enlarged in volume absorb moisture. For this reason, drying is necessary for an effective stabilization process. During aging, the final formation of the properties of the granules required in future polystyrene blocks takes place.
The time of this process depends on the size of the granules and the ambient air temperature. Ceiling device using ceiling polystyrene blocks: 1 - ceiling polystyrene blocks, 2 - mounting metal beams 3 - reinforcement of ribs, 4 - reinforcing mesh between the ribs, 5 - mounting retaining post (1 rack per 1 m2 of flooring), 6 - ordinary wall blocks, 7 - additional blocks. Next, you can start the main process, which consists in baking and molding polystyrene blocks. In this process, you need to use pneumatic transport, through which the aged granules are fed into the molding container . After that, hot steam from the steam accumulator begins to be fed into it. Under its influence, an independent baking of a block product occurs. The quality of the finished foam directly affects both the temperature and pressure of the steam, and the duration of its supply.
After the process is complete, the hopper doors open and the resulting block is obtained. Depending on the brand of expanded polystyrene, the whole process of baking with your own hands takes from 5 to 10 minutes. Ready-made blocks are sorted by hand with their own brands and stacked in a dry room. And always in an upright position. The matured unit is divided on a special machine into sheets of a given thickness.
The most popular sizes of foam sheets are 20, 30, 40, 50 and 100 mm. In a modern horizontal cutting machine, strings are installed that allow you to divide the block into several sheets at once, cutting off the excess from the edges of the workpieces. The finished sheets are beaten with your own hands on a vertical cutting. If necessary, blanks can be divided into sheets of the desired size.
Expanded polystyrene can not only be bought ready-made, but also made with your own hands. This does not require sophisticated equipment. The real benefit from such work is possible if large-scale production is planned, for example, during the construction of a house. If it is necessary to insulate a couple of walls, it is better to buy polystyrene foam. Due to its heat-insulating properties, polystyrene foam can be used as an external thermal insulation of the roof, foundation and walls.
Preparation for work
To make polystyrene foam with your own hands, you will have to perform a series of preparatory work, then to do everything quickly and efficiently. Products can be made in the form of plates or blocks.
It all depends on what kind of material is more convenient to use for work. For example, boards are used for insulation, they are glued to the surface. For the construction of any structural forms or for formwork, the use of blocks is required, they are additionally also reinforced.
After forming, the blocks have the following dimensions:
- width 25 cm; height 25 cm; length 95 cm.
Expanded polystyrene is 98% air, it is lightweight and inexpensive.
The process itself, how to make polystyrene foam at home, can be attributed to the category of simple, but demanding. A chemical reaction is accompanied by the release of formaldehyde volatile substances. If you do not observe caution, then poisoning is likely not only to the manufacturer, but also to others.
Production Scheme:
- the availability of raw materials (it is necessary to purchase special granules, which are the basis for creating the material); pre-foamer, with which the mass is created; a hopper for working, aging the material; polystyrene foam molds; storage of finished products, cutting and sorting; pneumatic conveying; steam generator ; compressor; receiver for steam; crusher for waste.
During manufacture, it is necessary to ensure that there is good ventilation in order to divert all the vapors generated during operation. It is recommended that work be carried out in a separate room.
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Properties of expanded polystyrene.
Production planning:
- Organization of the workplace, preparation of the necessary equipment. Purchase of granular polystyrene, which will be used as the main raw material. Granules are poured into a container to create the material. Saturation of the mass with steam at a certain temperature, aging, baking blocks or plates.
Before starting work, it is necessary to ensure the availability of tools and equipment such as:
- a container for mass; a steam generator; a steam accumulator (it is necessary to control the volume of steam); a compressor; hoppers for pellets, special forms for obtaining the material of the required parameters; a machine for cutting material; pneumatic transport; volumetric dishes, scales for determining the finished volume.
Schematic panel of expanded polystyrene.
An important stage is the purchase of raw materials, i.e. polystyrene granules.
Today it is not so difficult to do this, manufacturers offer bags with granules of 25 kg each. It is important to choose the right size, mass quality, country of manufacture. It is best to take raw materials from a trusted company whose product quality is distinguished by the required properties.
The choice of granule sizes depends on which polystyrene foam is required to be made.
The smaller the granules, the harder the material can be obtained. It should be noted how much time the granules have already spent in the warehouse. The longer the raw materials lay in the warehouse, the more time is required for foaming, steam treatment.
Failure to comply with the rules can lead to poor quality, the material will ultimately be not quite suitable for use, and this is a waste of time and financial resources. It is required to purchase raw materials correctly, take into account the processing time, and fulfill all the conditions for baking. An important step is cutting, since the thickness of the plates should be the same, discrepancies are not allowed.