Yongte has assisted client in optimizing WPC profile extrusion line resulting 40% increase in output efficiency

Recently, we received a technical support request from a client operating a 65/132 WPC profile extrusion line for WPC decking production, with a current 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. First, we collected the following production parameters:

Current Production situation:

① Machine: SJSZ65/132 WPC Profile Extrusion Line

② Product: solid WPC decking

③ Profile dimensions: 140 × 21 mm

④ Profile weight: approx. 3.5 kg/m

⑤ Calibration: 2 x240mm calibrators

⑥ Downstream cooling: 2000mm cooling baths

⑦ Haul-off: none installed

⑧ Current stable output: ~130 kg/h

⑨ Corresponding line speed: ~0.62 m/min

Our technical follow-up confirmed that the customer's production process maintained excellent product quality, with no deformation or insufficient cooling issues. Based on this, we advised them of the untapped production capacity potential. Further analysis of their extrusion parameters revealed the following operating conditions:

Current setup and operating data:

① Machine: SJSZ65/132 WPC Profile 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 adjust the extruder and mold temperature according to the production situation. Additionally, as extrusion speed increases, the cooling bath length should be extended to ensure faster product cooling.

After all adjustments were completed, the customer successfully increased production capacity to approximately 180 kg/h using the same production line to manufacture the same decking product.

Now in our newly designed WPC profile extrusion line, we have equipped servo motors that enable more precise speed adjustment and more stable operation. Additionally, the line features an 8-meter calibration table paired with 6-meter cooling baths to ensure sufficient cooling capacity for high-speed production.