Extruded polystyrene (XPS) closed-cell, rigid XPS insulation significantly improves the energy efficiency of unfinished exterior and interior walls for remodeling and new construction. In addition, the XPS boards provide thermal resistance with an R-value of 4.6 to 5.0, depending on their density, to create a comfortable indoor temperature and reduce utility bills. Moisture-resistant XPS panel insulation, with an absorption rate of 0.3 percent, resists moisture intrusion during and after application to help protect against damaging and unhealthy mold and rot.
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Lightweight, versatile, and simple to install, extruded polystyrene sheets typically come in 8-foot and 5-foot lengths, ranging from 16 inches to 4 feet wide and ¾-inch to 4-inches wide. The sheets come unfaced, and are covered with a foil facing, or laminated with plastic. The facing adds water resistance, and the lamination offers strength, but neither affects the sheets’ R-value. XPS sheets come in an array of colors (typically blue, green, and pink), based on the manufacturer, not insulating quality.
Flexible XPS boards come in various compressive strengths, making them ideal for numerous applications in all areas of the building envelope:
Manufacturing XPS insulation involves combining polystyrene crystals with special additives and a gas blowing agent. Manufacturers feed the mixture into an extruding machine that blends and melts it into a thick liquid. The liquid then gets processed through a die, which expands it into foam, shapes, cools, and trims it into standard-sized rectangular or square boards, with surfaces according to the intended use.
Specially designed machines produce XPS boards in smooth, rough, and grooved surfaces.
Demanding applications, like below-grade installation, utilize smooth XPS panels. Smooth, closed-cell XPS panels protect against absorption and diffusion due to long-term water exposure.
Rough surfaces increase the adhesion of the facade plaster.
Grooves in the XPS panel enhance wall drainage and thermal insulation for foundations.
XPS insulation offers many benefits contributing to an eco-friendly, healthy, durable, and safe building envelope.
XPS closed cell insulation, with an R-value of 4.6 and 5.0, gives it a high thermal resistance value, making it extremely energy efficient, by saving energy in buildings and reducing CO2 emissions.
100-percent recyclable XPS allows manufacturers to melt and reform the thermoplastic polystyrene resin into new XPS foam insulation.
XPS insulation’s high compressive strength allows it to withstand a high pressure of >300 kPa, so it can withstand more than lbs ft2 (30,000 kilos m2) with a maximum deformation of 10 percent, making it ideal for challenging applications:
XPS insulation provides water and freeze-thaw resistance, to protect the insulation’s thermal performance from damaging rot and unhealthy mold. In addition, the high permeability of XPS insulation makes it ideal for bathrooms and other high-moisture rooms.
Lightweight XPS insulation allows for easy application without irritating the worker’s skin.
Applying XPS insulation boards involves gluing the lightweight sheets to the substrate, which is much simpler than batts, blown-in fibers, or spray foam insulation. It is important to only use the manufacturer’s recommended foam-safe adhesive. The wrong glue can melt the foam. In addition, butt the sheets snugly together and seal joints with a manufacturer-recommended adhesive seam tape.
To insulate the stud, joist, and rafter cavities, cut the sheets to fit snug in the cavities, inserting them flush with the framing. To prevent airflow that can diminish the R-value, fill gaps along the edges with expandable insulation foam, safe for use with XPS. You can increase the R-value in two-by-six and larger dimension framing by inserting an additional layer of rigid foam insulation.
You can simply cut thin XPS sheets (less than 2-inches) by holding the straight edge of a utility knife along the cut line, scoring it about 3/4-inch deep. After scoring, lay the sheet on a table scored side up with the cut about 1-inch off the table. Firmly hold the sheet down and snap along the line. Trim the rough edges with the utility knife
For thicker sheets (greater than 2-inch), you will need a handheld drywall saw, or a table saw.
Installing 2-inch EPS boards on exterior sheathing requires additional furring strips or other structural supports. In addition, 2-inch XPS does not supply the strength needed to support the weight of the siding. Therefore, Sto strongly recommends that you check with your local building authority to determine the required type of additional support before installing 2-inch XPS as exterior sheathing.
Sto offers superior, simple-to-apply cladding solutions for applying XPS to an exterior wall system compared to XPS insulation boards: StoTherm ci XPS and StoPanel XPS ci. In addition, Sto XPS CI wall systems meet the requirements of fire, energy, and green building codes.
Sto XPS Wall Systems meets the requirements of NFPA 285 and NFPA 268 for use on non-combustible construction (Types I-IV).
Ch. 6: Energy Conservation, Efficiency and Atmospheric Quality (Section 606: Building Thermal Envelope insulation and Air Sealing) Alternative Compliance Path: ASHRAE 189.1-
Durable StoTherm® ci XPS, one of StoTherm® ci wall systems, is a drainable exterior insulation finishing system that incorporates high R-value XPS insulation into the wall system, and StoGuard® fluid-applied air and moisture barrier, with Owens Corning Foamular CI-C or Dow STYROFOAM™ Panel Core 20 insulation. StoTherm® ci XPS produces water and airtight air walls to ensure superior durability and thermal efficiency.
The unique, durable system sustains maximum curb appeal and lowers energy bills to save money. In addition, StoTherm® ci XPS can be finished with a variety of Sto textured finishes or specialty aesthetic finishes to accommodate your building’s design needs.
Lightweight StoPanel XPS ci prefabricated panels incorporate extruded insulation within the panel assembly, and create exterior wall cladding with excellent air and weather tightness, superior thermal performance, and long-lasting durability. In addition, architects and designers can choose from Sto’s numerous decorative and protective color and finish options.
StoPowerwall® ci energy-efficient stucco wall systems include StoGuard® air and water-resistive barrier, Owens Corning or Dow Type IV XPS insulation board, Sto DrainScreen, and Sto textured finishes.
StoPowerwall ci integrates continuous XPS insulation, air/moisture barrier, drainage, and Sto’s extensive collection of aesthetic surfaces in a hard coat stucco system.
Designers can use Sto’s unique Color System as a planning tool for choosing the colors for their architectural designs. The Sto Color System provides several benefits:
The Sto Color Collections include:
Sto’s extensive selection of finishes features pure white marble aggregate, acrylic polymers in various textures, and a wide range of color options to boost your design and harmonize with the surrounding environment. In addition, durable, high-performing Sto finishes resist dirt and water, protect the building’s facade, and enhance its curb appeal. Sto high-quality finishes include:
StoCast Finishes
Specialty Aesthetic Finishes
StoSignature
Sto Traditional Finishes
iQ Technology
Sto offers superior, sustainable, simple-to-apply, multiple code-compliant cladding solutions for applying XPS to an exterior wall system compared to XPS insulation boards. Drainable StoTherm® ci XPS and StoPanel XPS ci create high-performing, sustainable, and attractive cladding systems, improve indoor comfort and air quality, save both money and energy, and ensure long-term durability:
Single-Screw Extrusion:
The basic unit of the single-screw extrusion machine is the interface barrel and the screw, which comprise feeding, melting, mixing, and squeezing. The powerful driving force of the screw allows the material to be adequately melted and mixed, ensuring uniform extrusion. The single-screw extrusion machine had relatively low energy consumption and production costs. However, due to its limited ability to control the temperature and pressure of materials, it cannot satisfy complex processes and high-quality requirements.
Double-Screw Extruder:
The double-screw extrusion line has two parallel intermeshing screws that provide better mixing and distribution of materials. The temperature of the material can be adequately controlled because there are more heating and cooling zones. Therefore, it is suitable for more sophisticated and demanding production needs. Nonetheless, the initial investment and energy costs of double-screw gearboxes and motors are relatively high, raising the extruding line's overall expenses.
Blown Film Extrusion Lines:
Blown film extrusion lines are intended to manufacture plastic films and packing materials. The typical extrusion head forms the plastic molten stream into a bubble, which is later cooled down and solidified by a cooling ring and air flow.
Sheet Extrusion Lines:
Sheet extrusion lines focus on producing plastic sheets and are typically equipped with flat die heads. These heads create narrow plastic streams that are air or water-cooled to form solid sheets. Once cooled, the sheets are cut to size.
Co-extrusion Lines:
Co-extrusion lines allow for the simultaneous extrusion of multiple plastic materials through a single die head. This enables the production of multilayered products with varying surface qualities.
Profile Extrusion Lines:
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Profile extrusion lines utilize specific die heads to shape plastic profiles, such as window frames, decorative strips, and other complex sections. These profiles find applications in construction, automotive, and other industries.
Feed block & feed disk:
As stated earlier, the feeding device is responsible for conveying the raw material to other units in the machine. To make things work seamlessly, users should ensure that the feed block and the feeding disk are devoid of any dust, chips, or plastic residues. Also, users should pay careful attention to the gears and belt to see if they are functioning well. If they are damaged, it's better to replace them than to attempt a repair.
Die head:
While cleaning the die from the inside, users can make use of turpentine, diesel, or kerosene. But this doesn't imply that users should subject the die to dirty materials; otherwise, cleaning will turn out to be cumbersome. Before cleaning the die, manufacturers should ensure that the temperature of the extrusion die is low. If there's any paint on the die, it should be removed, and all surfaces should be thoroughly cleaned.
Melt pumps:
Users can either opt for preventative maintenance or predictive maintenance when it comes to maintaining the melt pump. In preventative maintenance, manufacturers can follow the standard maintenance schedules calculated based on operating hours or preset intervals. Predictive maintenance, on the other hand, is relatively more advanced, as it involves closely monitoring the melt pumps in real-time with analytics and insights to determine the ideal maintenance window.
Calibration table:
Users should familiarize themselves with the extrusion calibration table and its various systems. As a result, they will know how to take care of them appropriately. For instance, some calibration tables include water troughs, and these should always be kept clean. In fact, the surfaces of such troughs should be cleaned on both sides. Manufacturers should also use scrapers to get rid of stagnant water in the drying boxes and water troughs.
Haul-off unit:
Users should regularly lubricate the moving parts of this unit. When doing so, they should be generous, as too much lubrication can attract dust and grime. To avoid any unnecessary spillage, manufacturers should apply lubrication only to the parts that require it. The rollers and tracks should be cleaned from time to time to get rid of plastic residue. They should also be dried properly before any further operation.
Cutting unit:
Users should regularly clean the blades and, if necessary, sharpen them. When cleaning the blades, they should be thoroughly dried to prevent rust.
Food industry:
The food processing industry exploits the 120mm food extrusion line to manufacture numerous food items, including snacks, pasta, breakfast cereals, pet food, and vegetables. With its ability to produce distinct shapes and textures, the food extrusion line improves efficiency and streamlines production lines.
Plastic industry:
An important component of the plastic processing sector is the 120mm plastic extrusion line. It is used to make plastic sheets, pipes, profiles, films, and other goods. The extrusion line is ideal for mass manufacturing since it has a stable output and excellent product precision.
Construction industry:
The 120mm plastic profile extrusion line has several uses in the construction industry, such as the production of plastic doors, windows, and other architectural components. These materials are durable, adaptable, and resistant to moisture and insects, necessitating little upkeep throughout their lifespan. Furthermore, the profiles can be designed and engineered to have great thermal insulation properties, thus improving the buildings' energy efficiency.
Rubber and plastic industry:
The sole use of the rubber and plastic extrusion line is to produce plastic products on a huge scale. Such products are utilized in various industries including agriculture, automotive, toys, healthcare, electronics, etc., meeting the demand of each industry respectively.
Film and television animation:
The film and television animation industry exploits the double screw food extrusion line to make animated films or television series for children. Such films or series are mainly targeted at the preschool age stage so as to educate the children on certain knowledge and concepts.
Sports and fitness:
The sports and fitness industry makes use of the single screw food extrusion machine to manufacture sports food such as protein bars, energy bars, etc., as well as pet food. These products are designed to meet the needs of consumers who advocate sports and exercise, as well as the pets' needs for diet and nutrition.
Production Speed
To meet market demand, buyers should look for the speed at which the extrusion line can produce products. A fast extrusion line can produce more items in a short time.
Energy Efficiency
It is important to consider the energy usage of the extrusion line. A machine that uses less energy can help save money on electricity costs.
Flexibility and Versatility
Buyers should look for an extrusion line that can produce a variety of products. A flexible and versatile machine can help business owners adapt to different market demands.
Maintenance Requirements
Consider the maintenance needs of the extrusion line. Some machines require more maintenance than others. It is important to choose a machine that is easy to care for and maintains its performance over time.
Supplier Support
It is important to consider the support provided by the machine's supplier. Choose a supplier that offers reliable support and helps when needed.
Safety Features
When purchasing an extrusion line, it is important to consider the safety features of the machine. Safety is crucial for protecting workers and preventing accidents.
Types of Extrusion Processes
Buyers should consider the different types of extrusion processes the machine offers. It's important to choose an extrusion method that suits production needs.
Quality of Construction
Investment in an extrusion line is significant. Buyers should look for a machine built with high-quality materials to ensure its strength and reliability.
Technical Specifications
Consider the technical specifications of the extrusion line, such as its size, power, and capacity. These specifications will determine the machine's capabilities and performance.
Cost and Return on Investment
Lastly, buyers should evaluate the cost of the extrusion line and its potential for return on investment. Consider the machine's production efficiency and the income it can generate to make a financially sound decision.
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