SPC Floor Tile Turnkey Project - Stars Plas · 2020. 4. 8. · Cooling Mixer. Total Volume 2500L...

ADD: HuaChang Road, Science and Technology Zone Zhangjiagang, Jiangsu, CHINA Email: [email protected] Contact: Andy Fang Web: https://www.starsplas.com TEL: +86 512 56303759 FAX: +86 512 58535268 WhatsApp/Cell: +86 18913613799

Date: 28/11/2018

SPC Floor Tile Turnkey Project

Part Ι Project Evaluation

Profit Estimate Reference(All calculation should based on local marketing price):

Item Data

SPC Sheet Production Output 1000~1400m2/day | Half 20FCL

Production Estimate days 300 days/year

Annual Estimate Output 210,000 Sheet | 420,000 m2/Year

Sizes of Sheet after Extrusion 950x1220mm (1.2 square meters)

Production Cost 5~6 $/m2

Marketing Price in China 7~9 $/m2

Gross Profit per sheet 2~3 $/m2

mailto:[email protected]

https://www.starsplas.com/


Gross Profit per day 2,000~4,200 $ /day

Annual Estimate Gross Profit 600,000~1,260,000 $/year

Raw Materials, Additives, Consumables:

No. Item Formulation Reference Price Reference

1 CaCO3 200-225kg 60~90$/Ton

2 PVC Resin 75kg 1100~1200$/Ton

3 Recycled PVC Chips 50-60kg 400~550$/Ton

4 Stabilizer 3.3-6.5kg 1850~1980$/Ton

5 CPE 4~6kg 2100~2280$/Ton

6 PE-Wax 0.5~0.7kg 1650~1760$/Ton

7 Lubricant 0.7~1.3kw 1950~2050$/Ton

8 ACR 3-4.5kg 2100~2250$/Ton

9 UV coating Oil 12~18g/m2 0.15~0.2$/kg

10 PVC Film 1m/m2 0.5~0.6$/m

11 Wear layer 1m/m2 0.68~0.75$/m

12 Foam Layer 1m/m 0.63~0.92$/m2

Estimate for production cost 550~600 $/Ton in China

5~6 $/m2

EXW Price 7~8 $/m2

Marketing Price 10-12 $/m2




Part Ⅱ Equipment Details

1. Mixing System

Processing Procedure:

Section A (Weighing & Loading): Forklift → Open 25kgs Small bags(10+kinds of materials)

→ Weighing one by one → Loading into Mixer by Vacuum Conveyor

This is a semi-automatic system, you need to weighing by labor

Section B ( Mixing & Blending): Loading materials & Additives → High speed Turbo Mixer

→ Cooling Bending Mixer

Section C (Storage for Stand by): Screw Conveyor from Mixer to Silo→ 5T Silo for storage

→ Screw conveyor transfer from Silo to extrusion machine

Vacuum Loading System

Bag Unloading Unit S.S.304 for all parts

Safety Grid To avoid any packaging or tools falling into the loader

Dust Collector

1.5kw Blower for dust free venting 2pcs Solenoid valve, Back flushing for self cleaning.;

3pcs Anti-static bag filter ( with PTFE coating )

Pipe lines and pipe supporter

All pipes and platform was included Materials Suction pipes ( according calculation design ) Air Suction pipes ( according calculation design ) Piping clamp ( Morris type ) Pipe materials S.S304 & Plastic flexible pipes




Discharging Rotary valve Speed controller with a VSD ( variable speed drive )

Slide gate valve Adjust air flow at inlet air suction pipe

Vacuum pressure gauge Monitor the pressure during the pneumatic transportation

Vacuum Blower 7.5kw equipped with a VSD ( variable speed drive )

Vacuum Hopper 600L for materials loading 3pcs Solenoid valve, Back flushing for self cleaning.; 4pcs Anti-static bag filter ( with PTFE coating )

Compress air for Solenoid valve supply with accumulator tank(supplied by contractor)

Mixing System

High speed Mixer

Total Volume 800L

Effective Volume 600L

Motor 110kw Siemens Motor

VSD ( variable speed drive ) INVT/Siemens Inverter

Thickness of the Wall 16mm(8mm S.S.304+8mmQ235A), Others only use 10mm

Thickness of the Base cone 25mm(1Cr18Ni9Ti), Others only use 14mm

Sealing method Oil sealing + Labyrinth Sealing

Type of mixing blade linear 3-layer, S.S.304

Max. Loading capacity 280~350kg/batch

Rotating speed 700rpm(Speed adjustable)

Lid opening method By pneumatic, and lid has safe Interlinked switch

Cooling Mixer

Total Volume 2500L

Effective Volume 1850L

Motor 22kw Siemens Motor





Thickness of the Wall 12mm(6mm S.S.304+6mmQ235A), Others only use 10mm

Thickness of the Side Plate 20mm(1Cr18Ni9Ti), Others only use 15mm

Type of mixing blade Detachable, S.S.304

Rotating speed 100-120 rpm

Cooling time 4-6min/batch

Cooling Method Circulating water in water jacket, with Chiller better

Discharging DN300, pneumatic butterfly valve

Electrical Cabinet


Main Electrical Spare parts Siemens/Schneider

Temperature Controller RKC

Screw Conveying System & Platform structure




Option A Mixed compounds conveying silo(Same as the Layout of Mixing system option A)

Option B Platform with Buffer silo(Same as the Layout of Mixing system option B), it requires workshop height is more than 10 meters

Storage Silo for Mixed Silo 5Tons( Can service for two lines)

Screw loader 2.2kw/set

Platform Our team will come to measure and confirm the structure and Layout details

Buffer Silo

Silo Volume 5T ( Requires 12 Cubic Meters)

Materials of Silo S.S.304

2. SPC Floor Extrusion Line





Section A ( Extrusion System ): Screw Conveyor from 5T Silo → Feeding into Hopper Loader

→ Extruder → Extrusion through T-Die into 4-roller Calender

Section B ( Calender System ): Melt SPC from T-DIE → 4-roller Calender → 2-roller hot laminati

ng roller(PVC film & Wear Layer)

Section C ( Downstream System): Cooling roller for Laminated SPC Floor sheet → Drawer → C

utter → Automatic Vacuum Sucker

Item Technical parameters

Extrusion System - Ф92/188 Extruder

Color of machine Can be customized

Power of Extrusion Line 180kw

Length of Extrusion Line 23.2m

Loading Hopper




Feeding Power 1.5kw with VSD ( variable speed drive ) controll

er

Double screw feeder Better Performance is Stable Feeding

Level Sensor 2pcs, Linked with Alarm

Screw

Materials 38CrMoAIA

Diameter 92/188

Effective length 2500mm

Quantity 2pcs

The rotation speed 1~35±3 rpm

Thickness of nitrided layer 0.4~0.7mm

Thickness of tungsten carbide coating 2mm

Barrel

Material 38CrMoAIA

Barrel type Two-section, front section inlay alloy

Heating zones Six zones

Heating power 68kw

Temperature range 50~300℃

Cooling zones Six zones

Adapter Stainless steel 3Cr13, chromium plated, with inner

convergent flow type

Cooling system 5X0.55Kw Blower fans

Cooling medium Air

Thickness of nitrided layer 0.7~0.8mm

Thickness of tungsten carbide coating 2mm

Motor and Gearbox

Main motor 110kw,

Gearbox Helical gears: 20CrMoTi




Bearing:NSK/NTN

PLC Electrical Control

Motor VSD ( variable speed drive ) ABB/SIEMENS

Main electric elements Schneider

Vacuum exhausting system

Type Monoblock and hydroseal vacuum pump

Motor power (kW) 4

Working method of the motor Three-phase asynchronous motor

Vacuum degree (Mpa) 0~-0.075

Quantity of vacuum pumps 1set

Extrusion T-Die Mould

Width 1320mm

Thickness adjustable 2~6mm

Die Heater 9kw x 1, Temperature Range: 25~160℃

Four-roller Calender System




Roller Diameter Ф450mm

Roller Length 1500mm

Chromium coating 0.08-0.12mm

Surface roughness 0.025μm

Bearing block Integral forging materials

Roller Gap Controlling Independent

Speed range(m/min) 0.2～2 m/min

Reducer power(kw) 0.75 kw

8.1 Roller Temperature Controller




Pump power 2.2KW×4

pump flow 200L/min×4

Heat transfer media Conduction oil

Heating power 15KW×4

Heating pipe Stainless

Temperature controller RKC

Liquid level controller Taiwan

Temperature control range Normal-200℃

Heating method PID self-control，Control accuracy：±1℃

Cooling Rollers




Diameter Φ63mm

Quantity 36pcs

Width 1400mm

Cooling length 9.2meters

Haul-off Drawer

Diameter Φ220mm

Width 1400mm

Motor Power 3kw

Roller haul-off synchronization Available

Linear speed 0.2-2m/min

Opening and closing schedule 80mm

Center height 1100±20mm

Cutting System




Cutting method Cutting knife

Cutter material High quality high speed steels

Revolving gear Worm, worm gear

Shearing device QH11D precision shearing machine

Idler quantity 3pcs

Automatic Sucker with Stacking System

Unloading rack Length 3200mm, roller




Transducer Controlled by Infrared ray

Sucker Qty 4pcs

3.UV Coating Machine

Processing : Forklift → Vacuum Sucker Loading Station → Dust Cleaning → 1st Roller Coatin

g → 1st UV Drying → 2nd Roller Coating → 2nd UV Drying → Leveling → UV Drying → Con

veyor → Vacuum Sucker Packaging Station Item Technical parameters

1. Automatic Vacuum Sucker Loading Station

Reciprocating Frequency About 10 times/min(Adjustable)

Working Cycle Setting up Available

Position Setting up Available

Monitor and Controlling System PLC

2. Dust Cleaning Unit




Power 1.66kw

Frame and brace material Steel channel

Conveying roller material 45# seamless steel tube and steel core (Hard

chrome plating on the surface)

Conveying belt thickness 3mm

Supporting panel material and thickness Cold rolled plate, 1.2mm

Chain wheel 45#steel

Conveying motor 0.75kw RV worm wheel speed reducer motor

Speed control Transducer

Dust cleaning wall panel material Q235

Brush roller material Horsehair

Wall panel motor 0.37kw RV worm speed reducer motor

Dust blower power 180w(3pcs)

3. Four Meter IR Heater




Frame type Steel channel and rectangular steel tube

Supporting panel Cold rolled plate

Conveying roller material Steel core of 45# seamless steel tube (surface

has hard chrome plating)

Belt thickness 3mm

Heating tunnel material 1.5mm thick cold rolled plate

Heating power 1kw*9pcs

Leveling machine 4 pcs

Temperature controller with

Chain wheel material 45# steel

Cycloidal-pin speed reducer power 1.5kw

4. Single Roller Coating Unit (1st Layer)




Base and supporting panel Rectangular steel tube

Frame, coating wall panel and component material Q235 steel panel

Conveying roller material 45# seamless steel tube steel core(surface has

hard chrome plating)

Belt thickness 3mm

UV roller material Steel core of 45# seamless steel tube(wrapped

with UV rubber)

Calculating roller material Steel core of seamless steel (surface has hard

chrome plating)

Calculating roller adjustment Use hand roller to connect or leave

Varnish running box and groove material 1.2mm thick cold plate

Conveying roller and UV roller control 1.5kw×2pc RV worm speed reducer

Calculating roller control 0.75kw×1pcs RV worm speed reducer

Transducer Individual transducer

Cover and shrouding type Cold rolled panel

Varnish supplier Diaphragm pump

5. Three lamps UV Drying Unit






Conveying roller material Steel core of 45# seamless steel tube(surface


UV box material 1.5mm cold rolled plate

Blower 1.1kw×3pcs

UV lamp quantity 3pcs

Transformer quantity 3pcs

UV lamp and transformer total power 9.6kw

Chain wheel 45# steel

Motor 0.75kw RV worm wheel speed reducer


Cover material painted cold rolled plate

6. Single Roller Coating Unit (2nd Layer: Same unit as 1st Layer)




7. Four Meters IR Heater



Conveying roller material Steel core of 45# seamless steel tube (surface


Belt thickness 3mm

Heating tunnel material 1.5mm thick cold rolled plate

Heating power 1kw*9pcs




Leveling machine 4 pcs

Temperature controller with

Chain wheel material 45# steel

Cycloidal-pin speed reducer power 1.5kw

8. Five Lamps UV Drying Unit



Conveying roller material Steel core of 45# seamless steel tube(surface


UV box material 1.5mm cold rolled plate

Blower 1.1kw×5pcs

UV lamp quantity 3pcs

Transformer quantity 5pcs

UV lamp and transformer total power 9.6kw

Chain wheel 45# steel

Motor 0.75kw RV worm wheel speed reducer


Cover material painted cold rolled plate

9. 2m belt conveyor




Frame and brace material Steel channel

Conveying roller material 45# seamless steel tube and steel core (Hard

chrome plating on the surface)

Conveying belt thickness 3mm

Supporting panel material and thickness Cold rolled plate, 1.2mm

Chain wheel 45#steel

Conveying motor 0.75kw RV worm wheel speed reducer motor


10. Automatic Vacuum Sucker Packaging Station








4. Cutting & Slotting System


Section A (Loading): Forklift → Automatic Hydraulic Platform → Auto Sucker → Rolling Feeder




Section B( Vertical Cutting): Vertical Cutting →Rolling Feeder → Belt roller conveyor → climbin

g roller conveyor → Rolling Feeder to Slotting

Section C (Vertical Slotting): Belt Conveyor → Vertical Slotting Machine → Brushing Trimming

machine → Belt Conveyor to Horizontal Slotting

Section D (Horizontal Slotting): Belt Conveyor → Horizontal Slotting Machine → Brushing Trim

ming machine → Belt Conveyor to → Manual packaging / Foam Layer Laminating System(Optio

nal)

Flooring Specification Data

Length 950, 1220, 1850mm

Width 125-200mm

Thickness 4-15mm

Tolerance of finished floor

Length ±0.25 mm

Width ±0.025 mm

Straightness Longitudinal----±0,08 mm/1000 mm

Squareness ±0.03 mm/ 205 mm(board length/width＞5)

Tolerance of joint height ±0.03 mm

Fit tolerance ±0.05 mm

Specification of main equipment


1. Automatic Vacuum Sucker Loader





2. Vertical Cutting Machine




Feeding motor power 1.5kw

Speed 10-30m/min

The spindle motor power 15kw

3. Vertical Slotting Machine

Longitudinal double end tenoner capacity About 60pcs/min standard board, standard boar

d size 5×150×1220mm, 0.18m2 each piece

Feeding motor power 7.5kw

Speed 50-80m/min

The 1st 2nd 3th station spindle motor power 8kw×6

The 4th 5th station spindle motor power 5.5kw×4




4. Horizontal Slotting Machine

Feeding motor power 4 kw

Speed 25-50m/min

The 1st 2nd 3th station spindle motor power 5.5kw×6

The 4th 5th station spindle motor power 3kw×4

5. Electronic Controlling system

Control system PLC control

5. Foam Layer Laminating System(Optional)





Section A : Belt Conveyor → Flooring placement constraint system → The laminating system →

The cutting and trimming system → Packaging


Laminating width 80mm~400mm

Laminating length 900~2000mm

Speed ≤35m/min

Thickness 3~60mm

Total power 39.8KW (hot melt glue)

Total weight 2500KG

PLC MITSUBISHI

Motor CPG

In feed conveyor

This system is equipped with specially designed belt, passing the floors one by one

Motor and conveyor system

This system is equipped with frequency-converter and Cycloidal pin gear speed reducer.

This machine is motored by transmission shaft , conveyor roller and guide roller. All the laminate

d rollers are made of NBR (nitrile rubber buna) ,it is endurable. The frequency-converter can be

adjusted for making the machine running at the right speed according to the clients’ requirement

s.

Flooring placement constraint system

This system is designed for making the floors pass through the machine in the same placement.

We can control the straightness of the flooring line with floors which are with different width; thi

s system guarantees the straightness of the compacting of soft film and floors.

Cold glue spreader and drying system（ Hot melt glue as optional choice） The glue sprea




der system is consist with ANILOX roller and glue blade

The Users can adjust the glue amount by the speed between the glue spreader roller and drivin

g conveyor. The drying system is consisting with heating oven, far infrared heating light and drau

ght fans. The soft film goes through the drying system after coating the glue in order to volatilize

the solvent. The temperature of the drying system can be adjusted by the temperature controller

till meeting the right temperature.

The laminating system

The laminating system is consisting with four support rollers and laminating rollers. The gap of th

e support rollers and laminating rollers can be adjusted easily according to the thickness of the fl

ooring and soft film

The cutting and trimming system

After the flooring is laminated with the soft pad, the auto cutting machine is programmed to cut

off the soft pad by PLC system, after that, the flooring will transfer to the edge shaving side for

trimming the extra soft pad one by one.

Electronic system

All the electronic parts are designed reasonable, and adjusting easily.

6. Recycling System6 - SPC Crusher





Feeding leftover SPC materials → Crushing → Blowing into Silo → Storage for next Milling proce

ssing (Final results 3-8mm chips)


Model SWP630

Diameter of rotating blade 630mm

Quantity of fixed blade 9pcs

Rotating speed 480rpm

Quantity of fixed blade 4pcs

Diameter of screen sieve Φ6mm

Crushing capacity 700-850kg/h

Main motor power 44kw

Grinding chamber 610×820mm

Weight 5000kg

Dimension 2550×1100×1860mm(SWP630 crusher)

1500×1250×2500mm(Collector storage bin & Blower)

Electrical power 380V, 50Hz, 3P

6. Recycling System - SPC Miller





Feeding crushed SPC Chips(3-8mm) → Milling → Blowing into Vibrating Screen → Storage in 25

kgs bags for next Mixing processing


Milling area 4280cm2

Storage tank volume 1m3

Small board specification(L×W×T) 1250×950× (125-200) mm

Stainless steel grade 202

Bearing grade NSK, 319Z, 3213Z

Internal diameter of milling compartment 600mm

Quantity of rotor 1

Quantity of blade 32 pieces

Power of fan 5.5kw

Motor power 55kw

Output capacity 220-300kg/h

Mesh size 40-160μm

Dimension 1,900x1,700x3,900mm




Part Ⅲ Commercial Terms and Condition:

NO. Commodity Qty Price ($)

1 Manuel Mixing System

(Service For 2 Extrusion Lines) 1 65,000

2 SPC Floor Extrusion Line 1 135,000

3 UV Coating Machine


4 Automatic Cutting Slotting System (

Service For 2 Extrusion Lines) 1 258,000

5 Foam Layer Laminating System

(Optional, Service For 3 Extrusion Lines) 1 70,000

6 Recycling System (Crusher & Miller)


7 Formula, SAT & FAT Installation, Training-3 Months 1 30,000

FOB Shanghai Price 715,300

SAYS SEVEN HUNDRED FIFTEEN THOUSAND AND THREE HUNDRED U.S. DOLLAR

OFFER VALIDITY : 30 days

DELIVERY TIME: 90 days (after down-payment)

TERMS OF PAYMENT:

50% of total price as down-payment, and the other 50% should be p

aid before delivery, both by T/T. The rate of penalty (for delay of the

manufacture and delay of payment) is charged at 1 % for every 5 d

ays, odd days less than 5 days should be counted as 5 days.

WARRANTY : Mechanical parts & Electrical parts

12 months from starting and anyhow no longer than 14 months from

the date of delivery for the parts considered by the manufacturer to b

e defective.

Parts of normal wear are excluded from warranty.

EXCLUSIONS : Civil works.

Electrical cables connecting the different machines forming the system

with the main electrical control panel.

Installation and starting on the purchaser’s premises.

Cranes, minor metalwork and equipment that may turn out to be nec

essary during installation and starting on site.

Whatever else not specified in this offer.



SPC Floor Tile Turnkey Project - Stars Plas · 2020. 4. 8. · Cooling Mixer. Total Volume 2500L...

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Transcript of SPC Floor Tile Turnkey Project - Stars Plas · 2020. 4. 8. · Cooling Mixer. Total Volume 2500L...