PVC Foam Board Production Line: A Comprehensive Guide

PVC  foam boards, widely used in advertising, construction, and interior design, are lightweight yet durable materials. Their production combines advanced polymer science and precision engineering. Below, we break down the manufacturing journey from raw materials to finished boards.

1. Raw Material Preparation

(Suggested image: Raw materials and mixing equipment)

The PVC foam board production line begins with PVC resin, the primary component. The key additives of it includes:

Plasticizers to enhance flexibility

Stabilizers to prevent thermal degradation

Foaming agents to create cellular structure

Fillers (e.g., calcium carbonate) for rigidity

Pigments for coloration

These ingredients are precisely weighed using automated systems to ensure batch consistency. A typical ratio is 60-70% PVC resin, 15-20% fillers, and 5-10% additives.

2. Mixing and Compounding

Materials enter a high-speed mixer where temperatures reach 100–120°C. This step achieves:

Homogeneous blending of powders

Partial gelation of PVC particles

Activation of foaming agents

The mixture is then cooled to 40–50°C to prevent premature foaming and transferred to storage silos.

3. Extrusion Process

The heart of PVC foam board is a twin-screw extruder divided into zones:

Feeding zone: Material enters at 150–160°C

Plasticizing zone: Temperature rises to 170–190°C, melting PVC

Metering zone: Pressure builds to 200–250 bar

Die head: Shapes molten PVC into a continuous slab

Critical parameters like screw speed (15–25 RPM) and melt pressure are monitored via PLC systems.

4. Foaming Stage

As the material exits the die, dissolved gas from decomposing foaming agents (triggered at 160–200°C) expands rapidly. This creates a closed-cell structure of PVC  foam board with:

Density: 0.31–0.8 g/cm³

Cell size: 50–200 μm

Compression strength: 3–10 MPa

5. Calendering and Cooling

The foamed slab passes through a three-roll calender:

Adjusts thickness (common range: 3–20 mm)

Imprints surface textures (glossy/matte)

Rapidly cools material below 60°C using water-cooled rollers

This stage determines final dimensional stability and surface quality.

6. Cutting and Finishing

Automated systems handle:

Longitudinal cutting: Adjusts board width (standard: 1220/1560 mm)

Cross-cutting: Sets lengths (2440/3050 mm common)

Edge trimming: Removes irregular borders

Boards undergo UV coating (optional) for weather resistance or digital printing compatibility.

7. Quality Control

Key tests include:

ParameterMethodStandard

DensityISO 1183±0.05 g/cm³

Flexural strengthASTM D790>15 MPa

Fire resistanceUL94V-0/V-1 rating

Surface flatnessLaser scanning≤0.5 mm/m

Applications

Outdoor signage (5–8 year UV resistance)

CNC-carved decorative panels

Moisture-resistant bathroom partitions

Lightweight truck liners

Environmental Considerations

Modern plants implement:

Closed-loop water recycling (saves 30–40% water)

VOC abatement systems (95% emission reduction)

Regrind protocols (up to 15% scrap reuse)