EPS/EPP shape

molding machine

Hangzhou Epsole
Technologies Co., Ltd
EPS/EPP foam shape molding machine photo
High-efficient Energy-saving EPS/EPP molding machine

Ⅰ、 Frame Structure

➢The whole frame adopts Q345 high manganese steel

welded combination.

➢The frame surface is treated by ball blasting, zinc

coating to improve antiseptic performance.

➢Mold frame is constructed & supported by 4 main rods,

which can be removed and replaced separately for
maintenance, without disassemble the whole machine.

➢All-round safe barrier to ensure no access to the

working area of the equipment.
Ⅱ、The machine configuration
 International top brand key components：

Simens PLC & touch

Germany Japan SMC
screen (with wifi)
Gemu valve solenoid valves
Digital & Procedural --
Know the status of machine everywhere
through App , even making a parameter
adjustment.
Two hoppers feeding system : Forced
feeding , stable and high efficiency &
Zinc Coating process , anti-aging

The shock absorber pad at the

bottom, reduce the vibration of
the engine running

Use a frame joint to anti machine

vibration, keep the machine smooth.
 Use a detachable machine screw for easy
access and replacement in case of problems
with the machine

Add a layer of copper to the screw to reduce wear

and increase the length of use.
Through an insulating layer,make the
energy more stable, thereby reducing
energy consumption

Using the advancest pid steam valve

control system, the machine control is
more accurate, compared to friendly
business(Germany Gemu & DURIA),
more energy saving.
 Change molding system

Features of the equipment:

1. The mold change time can be replaced in about 20 minutes. The mold shift is fixed without
personnel to enter into the female and male mold to eliminate safety hazards;
2. The female and male mold adopts three-side air intake mode, and the speed is faster. The
molding is more stable;
3. The vacuum is used up and down, which saves time for the large surface mold products;
4. Using 4 sets of clamping hook mechanism, the size of the opening and closing cylinder is
smaller, and the required pressure is also lower than the same size machine, which effectively
reduces the failure rateof the hydraulic system, but can effectively ensure the sealing between
mold and surface without leaking.
 Fast-mould-change molding

* Using the guide rail, the material touch and the quick change frame,
after the mold is assembled in the assembly area,
the quick change frame is placed on the guide rail to the machine
position and converted to the machine guide rail, and the mold is
positioned by the positioning mechanism.
* Manual locking (automatic models do not need to be manually
involved), complete the docking of the material pipe, convert the internal
time of the previous die change to external time, greatly reduce the
downtime of the die change of the machine, and truly realize SMCD
(QCOT) .
* Improve equipment utilization, greatly improve the working
environment of the molder, improve work efficiency, save labor
costs, maintain maintenance, and improve worker safety.
The mold change time is about 20-30 minutes.
 One-button-mould-change molding

The one-button mould change system is optimized

and upgraded on the basis of the quick mould change
system, so as to achieve a faster mold changing time,
which can reach about 5 minutes, and better reduce
labor costs.

The biggest bright spot:

Compared with the machines produced by friends（Kurtz）,
our company's machines are compatible with the molds for
fast mold change and one-button mold change.
It is a new and advanced technology.
 Hardware configuration comparison table

Erlenbach,
Key parts Unit Epsole,China Kurtz, Germany FY, China
Germany

Touch screen pcs Siemens 15 "industrial PC 10.4 inches industrial PC 10.4 -inch 256 colors 10.4 -inch 256 colors

PLC system pcs modular modular modular Integral

Single valve locator & digital Single valve digital Central energy Single valve switch value
Steam system set
proportional control proportional control distribution system control
Vacuum and drainage Single valve locator digital Single valve digital Single valve switch Single valve switch value
set
systems proportional controal proportional control value control control
Angle seat valves of all
pcs GEMU, Germany GEMU, Germany GEMU, Germany Domestic Angle seat valve
system
Butterfly valves of all Taiwan and domestic
pcs GEMU, Germany GEMU, Germany USA
system butterfly valve
Solenoid valves of all
pcs SMC, Japan FSTOL, Germany Burkert, Germany Burkert, Germany
system
electric contact gauges pcs Digital PID Digital PID TECSIS, Germany AFRISO, Germany

Hydraulic solenoid valve pcs Bosch Rexroth, Germany Germany Wedges,USA Taiwan

Vacuum pump system set NASH, Germany SPECK, Germany NASR, America Domestic

High pressure steam

pcs Italy Germany Germany Domestic
tube
Heat treatment set yes yes yes yes

Antiseptic set Zinc coating Zinc coating No No

 Software configuration comparison table

Key system Epsole,China Erlenbach, Germany Kurtz, Germany FY, China

Motor protection system Motor protection Motor protection Motor protection Thermal relay protection

Multi filters automatic Primary filter automatic Primary filter automatic Primary filter manual
Air filter system
drainage drainage drainage drainage
mechanical pointer
Electrical Gauges Screen digital display Digital gauge mechanical gauge
gauge
Alarm system Triple-colors light multi-color multi-color single color

Efficient vacuum cooling system yes yes yes no

Filling gun fast-air-distribution
yes yes yes no
system
Steam pressure protection system yes no no no
Steam energy saving control
yes yes no no
system
Steam pressure control system digital proportional digital proportional Simulated scale switch value control

Air pressure control system digital proportional digital proportional Simulated scale switch value contro

Water pressure control system digital proportional digital proportional Simulated scale switch value contro
Air cooling pressure control
digital proportional digital proportional Simulated scale switch value contro
system
Pressurized cooling water system yes no no no
◆ EPS forming temperature: approx. 105 °C
◆ Cooling water of 30-35 °C will be sprayed to the
mould for 3-5 seconds to reduce the temperature on
the mould surface down to about 95 °C
◆ Vacuum scution. The water begins to evaporate as a
result of pressure dropping.
◆ Water evaporation is a heat-absorbing process, the
heat is taken away resulting in cooling products.
 Advantage of vacuum cooling: high temperature demolding

Vacuum cooling enables high temperature demoulding, greatly improves production speed
and saves energy consumption.
Mold temperature variation under vacuum cooling: 70-80°C -- 105 ° C
Mold temperature variation under water cooling: 40-50°C -- 105 ° C
u To heat 1kg water from 20°C to 100°C requires heat amount : 335 kj

u To transform 1kg water (100°C) to 1kg steam (100°C) requires heat : 2256 kj

u Conclusion: the demand of heat of evaporating 1kg water to steam is 7 times

more than the heat taken away from cooling by the water at 20°C, therefore
vacuum cooling is much more speedily than water cooling.It only takes two to
three seconds

u Since vacuum cooling takes away the heat inside the product, the product after
cooling contains less water, the water content is less than 0.5% and no heating
room settlement later.
 High-efficient Energy-saving EPS moulding machine

Energy Consumption Comparison Table

As product size:308*255*100; Erlenbach,

unit Epsole,China Kurtz, Germany FY, China
980g; B-SB--25g/l Germany

Technical data 12pcs/cycle 12pcs/cycle 12pcs/cycle 12pcs/cycle

Machine Model K1214S EHV 1345/1145（图1） K1214A(图2) SPZ1400

Actual usable moulding area m2 1.43 1.54 1.54 1.43

Space required m2 12 14 14 12.5

cycle time s/cycle 60 50 85 1OO

Steam consumption per cycle Kg/cycle 7 4 8 12

Water consumption per cycle L/cycle 40 22 45 120

Air consumption per cyle m3/cycle 1.3 1.1 2.5 2

Heating time per cycle s/cycle 12 10 20 28

Power consumption per hour kw 14 12 15.5 15

Steam consumption per ton

ton 6 4 8 11
of EPS
Steam chamber optional With chamber no no
◆ The accurate control of steam pressure is a key factor of
production effience. We tried on products increasing steam pressure
by only 0.02 bar, however the cooling time was increased by 100s.
Currently, most of Chinese machines are made of small pipe & valves,
thus high-pressure steaming has to be used.
◆ Machines equip big pipelines and valves, which allows low pressure
and big flow of steam while moulding. Enough steam can be supplied
in an instant to reduce cycle time and provide excellent production
condition.
◆ Sintering begins at 90C and complete shaping will be achieved at
115C. Forming pressure only 2-2.5 bar.
◆ Multi-spots heating realize most equal distribution of steam in the
mold chamber.
◆ Full digital PID control to control energy consumption precisely.
◆ The steam chamber adopts unique thermal insulation material to
realize mold cavities' insulation.
A factory has 4 automatic moulding machine（1750*1450mm).
Product size: 345*218*143mm ; each weight: 51g ; density:17g/l ; capacity:16 pcs/cycle
Consuming approx . 80 tons of raw materials per month.

Then we discuss the steam consumption and cost if two companies use two kinds of machines, one
company ordinary machines and one company use our EPSOLE machine.

Each ton of raw material needs to consume 14t of steam (Ordinary) and 6t of
steam (Epsole) , please see the chart below.

Comparison Steam Steam Steam

table consumption consumption consumption
(each ton) (each month) (each year)

Ordinary 14t 1,120t 13,440t

Epsole 6t 480t 5,760t
 Suppose our steam cost is 45 USD per ton.

Comparison Steam Cost Steam Cost Steam Cost

table (each ton) (each month) (each year)
Ordinary $ 630 $ 50,400 $ 604,800
Epsole $ 270 $ 21,600 $ 259,200

From this chart, we can see that it would save

345,600 dollars just one year !
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