EPS Sandwich Panel Line with ISO quality system

1.Scope of Supply:

1)Installation & test running for Buyer.

2)Sufficiently train operation method to Buyer's operators.

3)Reference document (in English): circuit diagram and operation instruction, etc

2.Payment: T/T 30% down payment, the balance to be paid before shipment.

3.Delivery Time: 100 days after receipt down payment.

4.Packing: export standard packing, seaworthy packing.

5.Quality Assurance: shall be according to relevant China quality standard.

6.Installation: 2 technicians will be dispatched to Buyer’s plant for installation & commissioning. Work period: about 5 days

The expense of round trip tickets, accommodation, safety and interpretation shall be covered by Buyer, additional pay $60 per day per person to the technicians.

7.Warranty: we guarantee one year’s warranty after test running. (The matters caused by Buyer’s fault and the lack of Buyer’s maintenance shall not be covered). And we offer lifelong technical service and fast-response technical support to Buyer.

8.Scope of work excluded (Buyer scope)

1)On-site wires and cables work

2)Lubricating oil, ISO-VG46 hydraulic oil.

3)Reference tools for installation, like travelling crane, orientation tool, etc.

4)Steel coil for test running.

GENERAL PRODUCT AND MACHINE CAPABILITY
Material Substrate: Steel sheet, galvanized or painted Pre-painted steel coils
Raw Coil Data: Maximum Width: 1260mm
Minimum Width: 1,060mm
Maximum Coil Weight: 5,000 Kg
Maximum Coil OD: 1260mm
Maximum Coil ID: 600mm
Minimum Coil ID: 500mm
5-Rib Trapezoidal and Corrugated Steel Yield Strength: G550
Lower Skin Steel Yield Strength: G300
5-Rib Trapezoidal and Corrugated Coil Thickness: 0.42mm BMT
Lower Skin Coil Thickness: 0.55mm BMT
Core Material: EPS (SL Grade Average Density 16kg/m3)
Maximum plant speed: 3-4 meters/minute (dry-run)
Actual throughput is length and thickness dependent
Panel width: ………………………………………… 1,000 – 1,260 mm
Panel thickness:……………………………………… 50 – 250 mm
Operating Specifications Air Supply (Clean and Dry): 6 Bar Minimum
Electrical Requirements: 380v-415v, 80amp peak load 50Hz/3 Phase+live+earth
Control: 240 Volt, DC
Hydraulic Power: 125 bar (1800 psi)
Temperature: 20°c - 35°c

EQUIPMENT AND SERVICES LIST
Semi-Automatic Continuous Panel Line requirements
1.Hydraulic Un-coiler with Sheet Guide 2 sets
2.5 Rib Trapezoidal and Corrugated Roll-Former 1 set
3.Semi-Automatic EPS Pusher Table and Milling Table 1 set
5. 5m Roller Press Bed
6. MPP Cut-off System with Interchangeable Cut Saw for Roof
7. 1 x Manual Hot Wire
8. 2 x 6m Manual Conveyer
9. Line Controls And Integration
10. Factory Test, Operation Manuals and Ship Preparation
11. On Machine Guarding Compliant With Australian Standards

Test material for line testing – To be supplied by buyer
● Line transportation
● Inline Sander for top side or ceiling side of EPS core
● Program change to have upload/download of batches direct from the office to the machine control panel via Ethernet or Wi-Fi connection

EQUIPMENT DESCRIPTION AND OPERATION REQUIREMENTS
ITEM 1: UN-COILER, SHEET GUIDE AND 5 RIB TRAPEZOIDAL &CORRUGATED ROLLFORMER
● Dual Level 5 Rib Trapezoidal and Corrugated Profile Roll-former;
● Wireless Pendant Control;
● 1 x Micro-ribbing Profiling System

Un-coiling for the 5 Rib Trapezoidal and Corrugated Roof Profile must be provided via a manual Un-coiler. Steel should be fed via the Adjustable Sheet Guide and through the Sheet cut into the rollformer. The Sheet Cut may be activated either manually or automatically in the event of a Batching Auto stop function.
In all forming units, the sheet is formed (Upside Down) in a continuous feed through the roll forming section of the unit. Guides within the Units are conveniently located to assist the ‘hands-free’ guiding of the coil through the Formers.


ITEM 2: SEMI-AUTOMATIC EPS PUSHER TABLE & MILLING TABLE
● Semi-Automatic End Milling of EPS Slabs (Finger Jointing)
● Pneumatic Pusher Table
● Automatic Extraction to be included
It is proposed that core material will be manually loaded into the milling table. The milling table using a series of Pneumatic Pushers guide the product through a series of Trimers that ‘Square’ and where required ‘finger Joint’ the material before it is fed into the Lead in Section of the Laminating Press. The core material is then passed on to the pusher table where the pusher rams will push the core material into the lead-in section.



ITEM 3: DE-COILER
Pictures above for reference only
The De-coiler Section must be supplied with Hydraulic Coil Mandrels rated to 4 Tonne including De-coiler Frame complete with Coil Saddles and Standard Coil adjustment System. The Hydraulic mandrels are supplied with Portable Hydraulic Power Pack and Coil Lifting Beam.


ITEM 4 & 5: LEAD IN SECTION & 5M ROLLERPRESS BED

The Lead In Section comprises the following important components:

● Sheet Guides;
● Upper and Lower, Male and Female Z-Lock Roll-forming;
● One (1) x Upper Manual Profiling Bars and One (1) x Lower Profiling Bars;
● Main & Floating Trimmers;
● Machine Drop Guards
● Main Sheet and Core Material Guides;
● Infeed Heaters;
● Standard Control Console with Push Button and Potentiometer Controls
● Standard ’Inverted Capillary’ 'lue System
● Extraction must be included

The Upper skin should be fed through the Sheet Guides and Sheet Cut; through the Roll-formers where the Male and Female Interlocking Panel Joint is formed. While this is occurring, Radiant Heaters located throughout the Lead In Section should heat the outer skin surface which is important to help the chemical reaction of the glue. Thereafter, a two (2) part Urethane is applied to the underside of the both Upper and Lower Steel skins before being pressed to the Core Material.The Core Insulating Material is fed to the Lead In Section where the sides of the Core material are trimmed to ensure squareness and also perfect width. The design of the Trimers also rebate the Upper edges of the Waste Dust generated by the trimming process is extracted to a nearby Dust Tower (to be supplied).

A ’Beader or Micro Profile’ should be applied to either or both of the Steel Skins.While this is occurring, Radiant Heaters located throughout the Lead In Section must heat the outer skin surface which is important to help the chemical reaction of the glue.

We require an Inverted Capillary Glue System which is used to apply a two (2) part Urethane to the underside of the Lower Steel Skin and also to the underside of the Upper Steel Skin (or Board as may apply). A Wiper System mounted on a Cam is used to oscillate continuously across the surfaces to mix the two part Urethane together before being continuously pressed together in the Main Press.

Following application of the adhesive to the substrate, the products (Steel and/or Board) are guided to the Core Insulating Material which then enters the Roller Press Bed. The purpose of the Roller press Bed is to hold the combination of products under even and continuous load while the adhesive cures sufficiently for the Sandwich panel to be cut & handled.


ITEM 6: MPP CUT-OFF SYSTEM WITH INTERCHANGEABLE CUT SAW FOR ROOF
The MPP Cut-off System is so described because it combines a number of Cut-off functions with a series of positional changes (if required) that are usually managed by several Line modules. Hilleng has developed an interchangeable ’All-in-One’ system that is capable of cutting a wide variety of Panel Types.
Linked to the Batch Data input at the Main Control Console, in automatic mode the MPP Cut-off will automatically measure the length of the Panel, clamp the Panel at the measured distance and complete the nominated cut type which could be a straight double or step cut to the Upper and Lower Skins of the Panel before unclamping the panel and returning to the ’Home’ position to await the next cut sequence.
For cutting the standard Wall Module (Spec 001), the Unit must notch the Upper and Lower, male and Female Joint of the Panel. A specially designed ’Silent cutter’ which is a type of shear must enter the Panel at the Notch in the Panel Joint and proceed to cut the Upper and Lower Skin of the Panel. The cut produced by the Silent Cutter must simultaneously creates a safety edge by downturning the cut edges of the panel but also create a sufficient gap to allow the hotwire cutter to enter the Panel to complete a cut type to the Insulated Core of the Panel. The bottom silent cutter must be interchangeable with a cut saw for the trapezoidal and corrugated roof profile.


ITEM 7: 1 X MANUAL HOTWIRE
1 x Manual hotwire system to cut the core to a step cut of a straight cut, a profile mounted plate on the side of the hot wire frame which is used for various step cut profiles. The unique manual design of this equipment allows for a quick and easy operation.


ITEM 8: 2 X 6 M MANUAL RUNOUT CONVEYORS
2 x 6 meter manual runout conveyor are to be supplied to be placed after the
Bandsaw to assist the machine operator to manually unload the panels from the machine.


ITEM 9: LINE CONTROLS AND INTEGRATION
The Line should use local control consoles to house PLC’s & Electronic Drives and to provide various levels of semiautomatic Control. All Control Consoles
should be linked via Communications Cable or Bluetooth/WiFi for the purpose of Systems Management and Remote Software Access (via Modem or USB (3) .
The Main Control Console should be fitted with a Bilingual 15” Colour Touch Screen or equivalent used by the Main machine Operator to input batch Information and to monitor and control certain machine functions including Emergency Stop Activation; Machine Height; Batch Summary Information; Cut Type; Heater Controls; Line Speed; and Glue Volume etc.
Inner Screens are used for Calibration adjustments.
Factory ‘Wet’ testing of the line is to be provided at the factory in China which the customer will attend. ‘Wet’ Testing means the line will be tested using adhesive to produce Laminated Sandwich Panels in the profiles and types specified.


ITEM 10: FACTORY TEST, OPERATORS MANUALS AND SHIP PREPARATION
The customer will supply Trial Coil and Core Materials in sufficient quantities need to conclude ‘Wet’ testing of the Line.
This includes pre-painted Coil Steel, EPS and Adhesive in accordance with the
specifications and quantities.


ITEM 11: ON MACHINE GUARDING COMPLIANT WITH AUSTRALIAN
STANDARDS
● Max width : 1260mm
● Thickness range : 50mm – 250mm
● Safety cages with inter lock switch (if cages are open the machine will not
start) as per Australian Standards on machine and run out tables enclosed
between rollers and safety stop buttons
● Notch, cutting system 60 to 250mm + hot wire
● Bellevue washers - used to get right tension on rollers. Adjustment increments on roller frame on all machines
● 75KW Motor min to be used on Sandwich Panel machine
● Omron or Schneider controller program need to be able to be retro adjusted
after install and by remote
● How many people are needed to run machine? Please specify
● Electrical wiring to Europe and Australian standards
● slider on back of machine to stop wastage decider end with sensor
● Wireless stop button