Recently, a client asked us to provide technical support for increasing production capacity by optimizing the operation of their SJSZ65/132 WPC decking production line, which currently has an output rate of 130 kg/h. The client aimed to increase production capacity but lacked clarity on optimization strategies. Upon receiving the email inquiry, our team promptly initiated technical consultation.
Firstly, Our technical follow-up confirmed that the customer's production process maintained excellent product quality, with no deformation or insufficient cooling issues.we collected the following production parameters:
① - Machine: SJSZ65/132 WPC Extrusion Line
② - Product: Solid WPC Decking
③ - Profile Dimensions: 140 × 21 mm
④ - Profile Weight: Approximately 3.5 kg/m
⑤ - Calibration: 2 × 240mm calibrators
⑥ - Downstream Cooling: 2000mm cooling baths
⑦ - Haul-off: None installed
⑧ - Current Stable Output: Approximately 130 kg/h
⑨ - Corresponding Line Speed: Approximately 0.62 m/min
These operating parameters will be crucial in determining the potential areas for improvement and the subsequent steps to enhance the client's production capacity. Based on this, we advised them of the untapped production capacity potential. Further analysis of their extrusion parameters revealed the following operating conditions:
① - Machine: SJSZ65/132 WPC Extrusion Line
② - Feeding Motor Speed: 550RPM
③ - Feeding Electric Current: 2.23A
④ - Extruder Motor Speed: 700RPM
⑤ - Extruder Motor Electric Current: 33.5A
We confirmed that the client's extruder is equipped with an AC motor controlled by an ABB inverter, featuring a maximum speed of 1500 RPM. Currently, the motor operates at only 700 RPM—less than half its rated capacity. For stable and efficient production, the motor can typically run at 1000-1100 RPM (approximately 70% of maximum capacity). We therefore recommended gradually increasing both feeding speed and extruder speed, ultimately maintaining the motor speed at 1000-1100 RPM while adjusting the feeding rate to keep the motor current around 50A.
At the same time, the customer also needs to make appropriate adjustments to the extruder and mold temperature based on the actual production conditions and material characteristics. Furthermore, as the extrusion speed increases, it is necessary to proportionally extend the length of the cooling bath to ensure that the product cools more rapidly and uniformly, thereby guaranteeing product quality and dimensional stability.
After all necessary adjustments were finalized, the customer was able to achieve a significant enhancement in operational performance, successfully increasing the overall production capacity to approximately 180 kilograms per hour. This improvement was accomplished without altering the fundamental structure of the existing production line, which continued to be utilized for manufacturing the same high-quality decking product as before.
Now, in our newly designed and highly advanced WPC profile extrusion line, we have integrated state-of-the-art servo motors that provide significantly more precise speed control and ensure exceptionally stable operational performance. These advanced servo motors allow for fine-tuned adjustments, enhancing both the efficiency and reliability of the entire production process. Furthermore, the extrusion line is equipped with an extended 8-meter calibration table, which works in seamless conjunction with 6-meter-long cooling baths. This configuration offers ample cooling capacity, effectively maintaining optimal temperature conditions even during high-speed production runs, thereby ensuring consistent product quality and dimensional accuracy.
