CO2 Foam XPS Production Line
Our ECOFEL series XPS lines run from 200 to 3,000 kg/h. We have helped launch numerous XPS production facilities for international companies.
- Output across six ECOFEL models
- 200–3,000kg/h
- XPS foam board lines supplied worldwide
- 300+
- Guaranteed board density range
- 25–50kg/m³
- Compressive strength the line can reach
- 1,000+kPa
Trusted By
One tandem line, from dosing to packaging
A high-torque twin screw melts and mixes, the blowing agent is injected, and a cooling single screw brings the melt to foaming temperature before the die and the downstream.
- 01
Raw material handling
Vacuum loading, digital recipes
Details - 02
TDS-D twin screw
Melting, mixing, dispersion
Details - 03
Blowing agent injection
CO₂ metering by temperature, pressure and mass flow
Details - 04
TDD cooling single screw
Cooling and homogenization
Details - 05
Die & calibrator
Board forming and sizing
Details - 06
Downstream
Haul-off, trimming, cut-off, stacker, packaging
Details
DCS Intelligent Control System
A Prelude to Industry 4.0. Pulling data from recipe management and operation history, then optimizing the parameters using big data. Extracting data from maintenance records and alarm history, remote analysis and technical support can easily be done through such notifications.
DCS intelligent control system helps you manage your production and maintain your equipment more effectively. Powerful industry PC leads your XPS production into the Big Data Era.
TDS95–TDD250
- TDS · primary extruder
- High-torque twin screw extruder: plasticizes GPPS and recycled PS, takes the blowing agent.
- TDD · secondary extruder
- Single screw extruder: cools the melt precisely before the die.
01 · Raw material handling
Fully Automatic Raw Material Handling System
Continuous and uniform feeding is a key step in producing excellent products. All recipe changes can be done using digital settings. Incorporated with our DCS intelligent control system, it manages production parameters and controls cost more effectively.
Our integrated vacuum loading system and raw material handling solutions can be customized according to individual factory circumstances. This ensures excellent housekeeping and a clean environment throughout the facility.
02 · Twin screw
TDS-D High Torque Twin Screw Extruder
In comparison to typical domestically produced compounding twin screw extruders, our extruders are very different, as we adopt TDS-D series high torque, which brings the specific torque of our extruders up to 10.3 Nm/cm3.
Our high torque twin screw extruders offer many advantages as follows:
- Maintain the lowest possible melt temperature during processing
- Minimize the usage of flame retardant additive whilst maintaining the same flame retardancy level
- Keep the colour of the product bright and fresh
- Excellent for producing high compressive strength boards
Highly modularized barrels and screws as well as blowing agent injection flange allow TDS-D twin screw extruders to have wider flexibility and suitability. All CNC manufactured barrels and screws assure the precise fit, providing excellent mixing and dispersion as well as optimum residence time distribution (RTD). This all saves additive usage, in addition to enhancing product quality.
Twin Screw Extruder
03 · Blowing agent
Blowing Agent System
Strike the Balance Between Cost and Quality.
Variable physical properties of CO2 make accurate metering a challenge. It involves temperature and pressure control, mass flow rate control, and a fine balance between processing parameters.
We have designed a CO2 system which controls all the key parameters, to ensure precise metering. Our multiple blowing agent injection system allows you to shift the product portfolio easily, quickly adjusting to suit different market conditions. This also assures constant quality and cost control, therefore maximizing your profit margins.
How to Control Your CO2 in XPS Production LineCompatible blowing agents
- CO₂
- Ethanol
- DME
- HFC
- HFO
- Butane
- Pentane
- LPG
Usually a portfolio of blowing agents is recommended to balance product cost, easy operation and thermal conductivity.
04 · Single screw
Innovative Cooling Single Screw Extruder
Temperature control is extremely important when extruding foam. The innovative barrel design of our latest single screw extruder has increased cooling capacity by 80% compared with traditional designs.
In addition to our super cooled barrel design, our latest screw profile increases renewal rate of molten materials, ensuring the cooling efficiency and homogenization of the polymer, yet decreasing the power consumption by 30%.
- cooling capacity, super cooled barrel
- +80%
- power consumption, latest screw profile
- −30%
Compared with traditional designs
05–06 · Downstream
Downstream
We provide complete downstream systems, including calibrator, haul-off, edge trimming, cut-off, stacker, and auto-packaging system. We customize the downstream system according to customer requirements, also adapting to existing building. Surface planner, surface groover, embossing, shiplap edge, and tongue & groove edge accessories can be online or offline to suit the product being produced.
Individual units (blowing agent dosing, cut-off, edge trimmer, haul-off, stacker, packaging) are also supplied to upgrade existing lines.
Main Cut-off Unit
Edge Hogger
Short-edge Milling Machine
Paternoster Cooling Tower
The boards you can make
What an ECOFEL line produces. Each model has its own suitable thickness range, so the thickness of your target market drives model selection.
- Thickness
- 10–200mmFull series, produced directly. Suitable range differs per model.
- Width
- 600 · 900 · 1200mm600 mm is the international standard. Other widths by changing the die or adding a slitter.
- Density
- 25–50kg/m³Guaranteed. Clients have run lower than 25 and higher than 50.
- Compressive strength
- > 1,000kPaHighest achievable on our lines.
- Thermal conductivity
- 0.024–0.038W/(m·K)Depends on solid recipe, blowing agent portfolio and board thickness.
- Throughput
- 200–3,000kg/hSix standard models, see below.
Insulation
- Energy-saving for building
- Pipe insulation
- High-speed railway track
High Compressive Strength
- Foundations of airport runways, Roadways
- Under slab, concrete floors
- Safety barriers
Other Potential Applications
- Aeroponics system
- Ceiling decoration
- Composited panels
Surface & edge, online or offline:Surface planingGroovingEmbossingShiplap edgeTongue & groove
ECOFEL Series Machine Models
Six standard tandem configurations. Final output depends on board specification, formulation and configuration.
Don’t know your kg/h yet? Work it back from monthly sales
m³ × density ÷ hours ÷ yield. Preliminary planning only, from How to Choose an XPS Production Line: Capacity, Configuration, Budget, and Factory Requirements.
| Model | Throughput (kg/h) | Transformer Required | Installed references |
|---|---|---|---|
| TDS75-TDD150 | 200–450 | 300 KVA | — |
| TDS75-TDD200 | 400–600 | 400 KVA | Turkey · 600 kg/hUSA · 600 kg/hMiddle East · 500 kg/h |
| TDS95-TDD250 | 600–1000 | 600 KVA | EgyptKuwaitLhasa · 3,600 m altitudeHangzhou |
| TDS110-TDD300 | 800–1300 | 800 KVA | Mega Insulation, Türkiye · 1,300 kg/hSaudi Arabia · 1000 kg/h |
| TDS135-TDD400 | 1500–2000 | 1000 KVA | China · 2,000 kg/h |
| TDS135-TDD500 | 2000–3000 | 1200 KVA | East Europe · 3,000 kg/h, 60 m/min |
Swipe the table sideways for references.The largest, TDS135-TDD500, yields 3,000 kg/h.10–100 kg/h lab lines for sheet, board or beads are also available.
Plan the plant
The layout of different models is almost the same. We will also make some minor adjustments to the layout according to your plant situation.
Latest project · Türkiye
1,300 kg/h for Mega Insulation
USEON has completed the commissioning of a new 1,300 kg/h XPS foam board production line for Mega Insulation in Türkiye, one of Türkiye’s leading insulation manufacturers exporting to more than 20 countries. Built around the TDS110-TDD300 tandem extrusion system, the line adopts CO₂ foaming technology.
- Line
- TDS110-TDD300 tandem
- Blowing agent
- CO₂
- Capacity
- up to 1,300kg/h
- Line speed
- up to 30m/min
- Main drives
- IE5 permanent-magnet motors
- Control
- Siemens PLC + industrial PC
Complete line
- Six-component loss-in-weight dosing
- TDS110 twin screw
- TDD300 single screw
- Leveling
- Pulling
- Milling
- Grooving
- Cutting
- Stacking
- Packaging
XPS lines in operation
Successfully supplied 300+ XPS Foam Board Production Lines to multiple countries globally
China2,000 kg/h XPS Production Line in China
EgyptHigh-Capacity XPS Foaming Line: TDS95-TDD250 in Egypt
Kuwait600–1,000 kg/h XPS Production Line in Kuwait
Saudi ArabiaXPS Extrusion Line in Saudi Arabia
Turkey1,000 kg/h XPS Production Line in Turkey
TurkeyTDS75-TDD200 XPS Foam Production Line in Turkey
USAXPS Production Line in USA
Middle EastXPS Production Line in Middle East
Why Choose USEON XPS Lines
Trusted by Industry Leaders and UNIDO
We have supplied XPS machinery to BASF, Owens Corning, ISOFOAM and Ravago, and Fortune 500 groups recognize the quality and reliability of ECOFELTM lines. As a strategic partner of UNIDO, we also support projects worldwide that phase HCFCs out of XPS production.
Save 40% on Your Investment
Our machinery qualifies for international quality and safety standards and is offered at a much more affordable price. Typically, we can help you save 40% of the cost, compared to European suppliers. We will ensure you with both satisfied products and service from our expert team and multilingual service team.
Over 300 XPS Lines Launched
To date, we have launched and delivered over 300 foam XPS extrusion lines to countries all over the world including Australia, South Korea, Saudi Arabia, Kuwait, Romania, Turkey, and more. Our number of consumers and locations continue to expand across the world, and we are confident that our rich experience will ensure you satisfaction in what we do.
Latest Technology
Our TDS-D twin screw extruder delivers a specific torque of 10.3 Nm/cm3, and our latest cooling single screw extruder has 80% more cooling capacity while using 30% less power. Innovation is one of our core values; work with us to stay at the cutting edge of XPS technology.
Turn-key Projects
Good equipment is only the first step of an XPS project. We work with you from the feasibility study and workshop design to production planning, warehouse logistics and recipe management, then train your staff to operate and maintain the line.
Technical Support and Service
Our experts and engineers are here to assist and guide you to solutions for challenges that you face and to optimize production performance. Through our operation of the new DCS intelligent control system, we provide effortless, remote, synchronized, and accurate technical support.
FAQs
Specification answers are also shown under Boards, Models and Plant planning.
How much is the biggest throughput of your machine?
The TDS135-TDD500 reaches 3,000 kg/h.
What blowing agents can be used?
ECOFEL series XPS foam board machine can work with CO2, ethanol, DME, HFC, HFO, butane, pentane and LPG etc. A blend of blowing agents is usually recommended to reach the balance of product cost, easy operation and thermal conductivity.
What is the lowest density and highest density your machine can make?
We can guarantee the lowest density of 25 kg/m3, and highest density of 50 kg/m3. Some clients run below 25 kg/m3 and above 50 kg/m3.
What is the highest compressive strength your machine can make?
Our XPS machine is able to produce a compressive strength above 1,000 kPa.
What’s the thickness range of the XPS boards?
Our full series of lines can produce from 10-200mm thickness directly. However, each model has its own suitable range, therefore thickness range of targeting market is the key determining factor when selecting machine.
What is the XPS foam boards width range?
The international standard width is 600mm, some countries have 1200mm and 900mm width. In principle, any width can be produced by changing die or adding slitting machine.
What is the thermal conductivity of XPS board?
The thermal conductivity (lambda value) falls between 0.024-0.038 W/(m·K), depends on the recipe of solid raw materials, portfolio of blowing agents, as well as thickness of the boards.
Does this line have to work 24 hours?
Yes, this line has to work 24 hours. Because every start-up will take a couple of hours to heat up and waste at least one hour of scrap.
How much space does it require for XPS project?
It varies from model to model.
Generally, 70m x 8m x 8m is the minimum requirement for production line only. Minimum 2,000sqm is required for the whole plant.
How many people are needed for one production line?
The number of personnel required for each production line varies based on its output and whether it is equipped with an automatic packaging machine.
Model: TDS75-TDD150
| Positions | Person with Automatic Packaging | Person without Automatic Packaging |
|---|---|---|
| Feeding & Forklift Operator | 1 × 2 | 1 × 2 |
| Machine Monitoring | 1 × 2 | 1 × 2 |
| Crosscut & Milling Operator | 1 × 2 | 1 × 2 |
| Packing Operator | / | 2 × 2 |
| Palletizing & Forklift Operator | 1 × 2 | 1 × 2 |
| Granulation and Regrind Operator | 2 | 2 |
| Main Machine Operator | 1 | 1 |
| Mechanic and Electrician | 2 | 2 |
| Total Person | 13 | 17 |
Model: TDS135-TDD400
| Positions | Person with Automatic Packaging | Person without Automatic Packaging |
|---|---|---|
| Feeding & Forklift Operator | 1 × 2 | 1 × 2 |
| Machine Monitoring | 1 × 2 | 1 × 2 |
| Crosscut & Milling Operator | 2 × 2 | 2 × 2 |
| Packing Operator | / | 2 × 2 |
| Palletizing & Forklift Operator | 1 × 2 | 1 × 2 |
| Granulation and Regrind Operator | 3 | 3 |
| Main Machine Operator | 1 | 1 |
| Mechanic and Electrician | 2 | 2 |
| Total Person | 16 | 20 |
Typically, if you don't opt for automated packaging equipment, you'll need an additional 4 workers to ensure the smooth operation of the production line.
Here is a brief introduction to these positions:
- Feeding & Forklift Operator: Transports raw materials to the feed bin and must be able to operate a forklift.
- Machine Monitoring: Monitors the operational status of the main machine and performs basic operations.
- Crosscut & Milling Operator: Controls the stability of XPS boards dimensions.
- Packing Operator: Manually packs products in the absence of an automatic packaging machine.
- Palletizing & Forklift Operator: Stacks and arranges finished products neatly into the finished goods warehouse.
- Granulation and Regrind Operator: Processes waste and trimmed materials during production into granules for reuse.
- Main Machine Operator: Adjusts system parameters when changing product specifications.
- Mechanic and Electrician: Maintains and repairs machinery to ensure the smooth operation of the production line.
Do you make lab-scale machine for foam extrusion?
Yes, we do.
We provide a 10–100 kg/h lab line for foam extrusion. The final product can be sheet, board or beads.
Can I purchase just a specific unit of the production line, such as the main cut-off machine or a blowing agent dosing unit?
Absolutely. We offer both complete production lines and individual functional units to enhance your existing production lines. Available units include the blowing agent dosing system, cut-off machine, edge trimmer, haul-off machine, stacker, packaging machine, and more.
Please consult with our expert; sometimes a small change can lead to significant improvements.
Which countries and regions are your equipment sold to?
Our XPS foam line has been sold to many countries around the world and has helped our customers successfully put into production more than 300 production lines.
These countries are mainly as follows:
- Australia
- Azerbaijan
- Brazil
- China
- Egypt
- Georgia
- Hungary
- India
- Kazakhstan
- Kosovo
- Kuwait
- Malaysia
- Moldova
- Morocco
- Oman
- Pakistan
- Poland
- Qatar
- Romania
- Saudi Arabia
- South Korea
- Turkey
- Ukraine
- United Arab Emirates
- United Kingdom
- United States
- Uzbekistan
- Vietnam
Get a quote
Tell us your board specification, target output and blowing-agent route.
- 01Output check
- 02Layout & utilities
- 03Reference visit
Cliff Zhang
Head of Foam Extrusion Division
Polymer foam extrusion, extrusion machinery R&D and international business development.