Cellulose InsulationTechnology Fibretec Production Lines Succeed through green technology – Print money with used newsprint! 20 Fibretec 1000 Fibretec 1000 Basic economical system 1,000–1,200 kg/hour 70–80 bags/hour 21 21 The Fibretec 1000 is an economical system for those entering the cellulose-insulation manufacturing business. It consists of a basic solution with highquality equipment optimised for 1,000 kg/hour capacity. The manually operated paper-feeding and insulation-packaging systems are easy to use and control. With this system, the recycled paper arrives at the factory in loose form. Preliminary crushing is performed by a sturdy hammer mill. Final refining is handled by a powerful refiner that transforms the paper into very fluffy insulation, for the best coverage and lowest settled density. At the end of the line, the insulation is packed into paper sacks by a screw-driven packaging unit. Dust collection is performed effectively via separation of process 3 6 air from the material flow – this is done by cyclone separators and by direction the air through the system’s self-cleaning dust-filter unit. The Fibretec 1000 is offered with several automation levels. An automated paper-feeding system makes it possible to use bales of compressed paper as raw material. Also, two types of packaging systems are available. The insulation can be packed into pre-fabricated paper sacks or pre-fabricated plastic sacks. For full flexibility, several optional items are offered: a chemical pulveriser for improved fire-retardant properties of the chemical additives and a sparkdetection and extinguishing system for greater plant safety. 7 8 23 5 14 4 12 7 15 3 2 24 13 10 11 1 17 8 9 1. 2. 3. 4. 5. 6. 7. 8. Pre-handling Table Feeding Conveyor Hammer Mill Waste Separator Blower 1 Cyclone Separator 1 Paper Surge Bin Feed Device for Chemical Additive 1 9. 10. 11. 12. 13. 14. 15. 16. Feed Device for Chemical Additive 2 Chemical Blower Blower 2 Refiner Blower 3 Cyclone Separator 2 Fibre Surge Bin Packaging Machines 19 17. 18. 19. 20. 21. 22. 23. 24. 25. 18 Upper Pressing Belt Lower Pressing Belt Weighing Conveyor Dust-Filter Unit Piping Electrical Control System Spare Parts Chemical Pulveriser (Option) Spark-Detection & Extinguishing System (Option) 9 Technical Data Effective capacity: 1,000 kg/hour, 16 hours/day, for ~12,800 kg/day (with 80% duty cycle) Required space: ~400 m2 + ~300 m2 for storing the raw material and final product Free height of the hall: At least 8,000 mm Power supply: Voltage: 400/230 V, 50 Hz; connected power ~365 kW (without optional items) Compressed-air supply: Min. pressure 0.6 MPa, max. 0.7 MPa, flow rate ~600 l/min 16 Water supply: Min. pressure 0.2 MPa, max. 0.6 MPa (only with optional item 25) Operators: 4–5 persons per shift Auxiliary equipment: 1 forklift truck, 1–2 hand pallet trucks Paper sack information Dimensions of a filled sack: 1,000 × 500 × 250 mm (H × W × D) Weight of a filled sack: 13–15 kg (adjustable) Fibretec 1500 Fibretec 1500 Automated system 1,500–1,800 kg/hour 100–120 bags/hour (24) Advanced and automated system The Fibretec 1500 includes everything needed for manufacturing cellulose insulation at up to 1,800 kg per hour. An advanced version equips the solution with an automated paper-feeding system that takes paper bales as raw material – the feed of paper to the process is handled automatically. Also, using recycled paper collected from households or processing surplus newsprint from printing houses is possible. The fully automated version is complete with automatic packing. In the first stage, the paper is shredded by an automatic shredder. The second stage is refining, performed by a powerful refiner that transforms the paper into very fluffy insulation, yielding the best coverage and lowest settled density. Dosing of the chemical additives is managed with high precision by volumetric dosing units. Optionally, the chemical dosing system can be equipped with weighing sensors and hoists for handling 1,000 kg chemical sacks. 4 13 13 10 14 9 5 15 3 12 11 8 17 6 16 7 18 1. 2. 3. 4. 5. 6. Feeding Conveyor Paper-Shredder Blower 1 Cyclone Separator 1 Paper Surge Bin Dosing Device for Chemical Additive 1 Dosing Device for Chemical Additive 2 8. 9. 10. 11. 12. 13. 14. 15. 16. Chemical Blower Waste Separator Blower 2 Refiner Blower 3 Cyclone Separator 2 Fibre Surge Bin Hydraulic Press Flat-Foil Sealing Device 17. 18. 19. 20. 21. 22. 23. 24. Weighing Conveyor Belt Conveyor Dust-Filter Unit Piping Spare Parts Electrical Control System Chemical Pulveriser (Option) Spark-Detection & Extinguishing System (Option) 11 Technical Data Effective capacity: Required space: Free height of the hall: Power supply: Compressed-air supply: 19 13 2 7. 1 20 22 4 Packaging of the insulation can be performed either by a manual system using pre-fabricated paper sacks or by an automated packaging system that uses a plastic-bag form, fill, and seal unit operated with plastic foil. Effective dust collection is ensured by cyclone separators that separate the process air from the material flow and by the air being passed through a self-cleaning dust-filter unit. Offered as optional extras are a chemical pulveriser for improved fire-retardant properties of the chemical additives and a spark-detection and extinguishing system that makes for greater plant safety. 19 1 1,500 kg/hour, 16 hours/day, for ~19,200 kg/day (with 80% duty cycle) ~400 m2 + ~400 m2 for storing the raw material and final product At least 9,000 mm Voltage: 400/230 V, 50 Hz; connected power ~465 kW (without optional items) Min. pressure 0.6 MPa, max. 0.7 MPa, flow rate ~600 l/min Water supply: Min. pressure 0.2 MPa, max. 0.6 MPa (only with optional item 24) Operators: 2–3 persons per shift 1 forklift truck, 1–2 hand pallet trucks Auxiliary equipment: Packaging Plastic foil: Finished bags: Width of foil roll 1,450–1,500 mm, foil thickness 70–110 μm Length 780–800 mm (adjustable, width 380–400 mm, thickness 325–350 mm, weight 13–15 kg (adjustable, accuracy ± 0.5 kg Fibretec 2000 Advanced automated system The Fibretec 2000 represents the highest technology in the cellulose-insulation manufacturing industry. This production line is optimised for a capacity of at least 2,000 kg per hour. Only one key operator is needed to keep production running smoothly, while anther takes care of the product storage. The insulation is created from the paper through a highly effective two-stage process. An unmanned shredder breaks the whole paper bales and handles the shredding. In the second stage, refining is performed by the powerful refining unit, which transforms the paper raw material into very fluffy insulation, giving you the best coverage and lowest settled density. For the Full Benefits of Eco-efficiency 2,000 kg/hour 135 bags/hour The chemical additives are precisely dosed and continuously weighed before they are mixed together, to ensure the precise mix ratio desired and to control consumption of costly additives. Thanks to the use of hoists, it is easy for the operator to handle heavy 1,000 kg chemical bags with no fuss. 2 4 1 15 21 5 10 9 11 2 16 12 6 8 7 3 17 (23) 18 1. 2. 3. 4. 5. 6. Bale Conveyor Shredder Blower 1 Cyclone Separator 1 Paper Surge Bin Dosing Device for Chemical Additive 1 Dosing Device for Chemical Additive 2 8. 9. 10. 11. 12. 13. 14. 15. 16. Chemical Blower Waste Separator Blower 2 Refiner Blower 3 Cyclone Separator 2 Air-Lock Valve Fibre Surge Bin Hydraulic Baler 17. Flat-Foil Fill, Form, and Seal Device 18. Belt Conveyor 19. Dust-Filter Unit 20. Piping 21. Electrical Control System 22. Spare Parts 23. Chemical Pulveriser (Option) 24. Spark-Detection & Extinguishing System (Option) • Eco-friendliness – significantly less embodied energy than in fibreglass or rock-wool insulation • A self-sealing insulation material, minimising unwanted air leaks • Excellent thermal insulation value • Outstanding acoustic properties also • Breathability, evening out the moisture in the structures • Fire-safety: the material doesn’t catch, propagate, or spread fire • Resistance to rot, fungal growth, and pests • Strong adhesion to the surrounding structures • Local manufacture from recycled paper • User-friendly installation – safety, no cutting, and no waste The Increasing Demand for Sustainable Building Products With cellulose-fibre insulation, a house can be converted into a carbon sink with ease. Cellulose insulation is an ecologically sound and economical thermal and acoustic insulation material, for new and renovated buildings alike. It is a green material manufactured from recycled newsprint. Non-toxic natural minerals are used to protect the insulation material against fire and rot. • Thermal conductivity: ~0.040 W/mK (actual values as determined and approved by local authorities) • Resistance to fire: Cellulose fibre does not maintain or spread fire (actual classification based on local requirements) • Conductivity of air: 80–120 × 10–6 m3/msPa, depending on installed density 5 Technical Data Effective capacity: Required space: Free height of the hall: Power supply: Compressed-air supply: 14 Properties of Cellulose Fibre 14 The insulation is packaged by the fully automated hydraulic baler and bag form, fill, and seal unit. Dust collection is handled highly effectively through a two-part solution: cyclone separators keep the process air separate from the material flow, and the air is led through a self-cleaning dust-filter unit. For an even more complete system, the customer can choose a chemical pulveriser to improve the fire retardant properties of the chemical additives and/or a spark-detection and extinguishing system that increases safety at the plant. Both are optional extras. 13 19 20 (24) 7. 16 Why Cellulose Insulation? Fibretec 2000 Automated advanced system 17 2,000 kg/hour, 16 hours/day, for ~25,600 kg/day (with 80% duty cycle) ~450 m2 + ~600 m2 for storing the raw material and final product At least 9,000 mm Voltage: 400/230 V, 50 Hz; connected power ~485 kW (without optional items) Min. pressure 0.6 MPa, max. 0.7 MPa, flow rate ~600 l/min Water supply: Min. pressure 0.2 MPa, max. 0.6 MPa (only with optional item 23) Operators: 2 persons per shift 1 forklift truck, 1–2 hand pallet trucks Auxiliary equipment: Packaging Plastic foil: Finished bags: 1,000 × 500 × 250 mm (H × W × D) Length 780–800 mm (adjustable, width 380–400 mm, thickness 325–350 mm, weight 13–15 kg (adjustable, accuracy ± 0.2 kg Use of cellulose insulation The usual methods for installing cellulose insulation are blowing and spraying. The result of both is seamless insulation that fills the entire cavity perfectly. Using blowing and spraying methods in installation ensures that the adhesion of the insulation to the structures remains unchanged and strong over the years. Cellulose-fibre insulation can be installed manually or with special blowing or spraying machines. Thanks to the convenient installation methods, no cutting of the insulation material is needed. The Blowing method is commonly used for horizontal and diagonal structures – for instance, with attics and floors and for closed walls. The dry insulation material is blown into the cavity. This fine-grade material penetrates even the smallest of holes well and covers the entire cavity precisely and seamlessly. Spraying can be used with vertical structures, such as walls. The insulation material is moistened with a mist of water while it is sprayed onto the open structure. A seamless and draught-free insulation layer is achieved even in narrow and complicated spaces. After drying, the insulation adheres well to the surrounding structures, which prevents separation from the structural elements. Green Technology Fibretec Production Lines Walls Density of 30–35 kg/m3 Exterior and interior walls (spray-on method) Attics Density of 25–30 kg/m3 Density of 40–50 kg/m3 Vertical cavities (dry-blowing method) Ceilings Density of 40–50 kg/m3 Floors Density of 30–40 kg/m3 Makron’s cellulose-insulation technology provides a turnkey solution for manufacturing cellulose insulation from recycled newsprint, with all of the necessary equipment and services. The delivery provides all the machinery, piping, and cables, along with the full electrical control system needed for the processing plant. The services include supervision of installation and start-up and even training of the customer’s personnel. Furthermore, Makron can assist in addressing many questions related to end product know-how. The following amounts of raw materials are needed for producing 1,000 kg of cellulose-fibre insulation (figures are approximations): • 800–900 kg recycled paper (sorted, dry newsprint) • 50–100 kg boric acid (H3BO3) • 50–100 kg borax decahydrate (Na2B4O7*10H2O), or borax pentahydrate (Na2B4O7*5H2O) • 70 paper or plastic bags for packaging Makron Technology, expertise from Finland. Comprehensive service concept Makron is your partner for production machinery. Today Makron supplies technology and equipment for manufacturers of cellulose-fibre insulation, log homes, and prefabricated timber houses. The professionals at Makron serve customers in line with a total service concept covering design, machine manufacture, supplies, installation and start-up, training, and maintenance. Our service is accompanied by a customer-specific investment study, which enables improving the customer’s competitiveness, production capacity, and quality. Makron Technology Vanha Messiläntie 4 FI-15860 HOLLOLA, FINLAND Tel. +358 3 859 500
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