Cellulose Insulation Technology Fibretec Production Lines

7/24/2019 Cellulose Insulation Technology Fibretec Production Lines

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Cellulose Insulation

TechnologyFibretec Production Lines



The Fibretec 1000 is an economical system for

those entering the cellulose-insulation manufacturing

business. It consists of a basic solution with high-

quality 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

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 spark-

detection and extinguishing system for greater plant

safety.

Fibretec 1000

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

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 (adjustab le)

1. Pre-handling Table

2. Feeding Conveyor 3. Hammer Mill

4. Waste Separator

5. Blower 1

6. Cyclone Separator 1

7. Paper Surge Bin

8. Feed Device for Chemical

Additive 1

9. Feed Device for Chemical

Additive 210. Chemical Blower

11. Blower 2

12. Refiner

13. Blower 3


15. Fibre Surge Bin

16. Packaging Machines

17. Upper Pressing Belt

18. Lower Pressing Belt19. Weighing Conveyor

20. Dust-Filter Unit

21. Piping

22. Electrical Control System

23. Spare Parts

24. Chemical Pulveriser (Option)

25. Spark-Detection & Extinguishing

System (Option)

1

2

3

4

5

6

21

20

1918

15

14

13

12

1124

10

8

7

9

23

21

3 7 8

16

Fibretec 1000

Basic economical system

1,000–1,200 kg/hour

70–80 bags/hour

9

17



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 pri nting 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 i nsulation, 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.

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 bei ng 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 andextinguishing system that makes for greater plant

safety.

Fibretec 1500

1. Feeding Conveyor

2. Paper-Shredder3. Blower 1


5. Paper Surge Bin

6. Dosing Device for Chemical

Additive 1


Additive 2

8. Chemical Blower

9. Waste Separator 10. Blower 2

11. Refiner

12. Blower 3


14. Fibre Surge Bin

15. Hydraulic Press

16. Flat-Foil Sealing Device

17. Weighing Conveyor

18. Belt Conveyor 19. Dust-Filter Unit

20. Piping

21. Spare Parts




System (Option)

1

2

3

4

5

6

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2220

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1211

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1 11

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Fibretec 1500

Automated system

1,500–1,800 kg/hour

100–120 bags/hour

(24)

Technical Data







Operators: 2–3 persons per shift


Packaging

Plastic foil: Width of foil roll 1,450–1,500 mm, foil thickness 70 –110 μm

Finished bags: Length 780–800 mm (adjustable, width 380–400 mm,

thickness 325–350 mm, weight 13–15 kg (adjustable, accuracy ± 0.5 kg

4 13

13



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 throu gh a

highly effective two-stage process. An unmannedshredder 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.

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.

The insulation is packaged by the fully au tomated

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.

Fibretec 2000

1. Bale Conveyor

2. Shredder

3. Blower 1


5. Paper Surge Bin


Additive 1


Additive 2

8. Chemical Blower

9. Waste Separator

10. B lower 2

11. Refiner

12. B lower 3


14. Air-Lock Valve

15. Fibre Surge Bin

16. Hydraulic Baler

17. Flat-Foil Fill, Form, and Seal

Device

18. Belt Conveyor

19. Dust-Filter Unit

20. Piping


22. Spare Parts



System (Option)

1

2

3

4

5

6 7

21

2019

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17

16

15

14

13

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9

8

10

(23)

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Fibretec 2000

Automated advanced system

2,000 kg/hour

135 bags/hour

(24)

17

Technical Data







Operators: 2 persons per shift


Packaging

Plastic foil: 1,000 × 500 × 250 mm (H × W × D)

Finished bags: Length 780–800 mm (adjustable, width 380–400 mm,

thickness 325–350 mm, weight 13–15 kg (adjustable, accuracy ± 0.2 kg

Properties of Cellulose Fibre

• 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

Why Cellulose Insulation?For the Full Benefits of Eco-efficiency

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 ininstallation 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 cavityprecisely 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.



Makron Technology, expertise from Finland.

Makron is your partner for production machiner y.

Today Makron supplies technology and equipment

for manufacturers of cellulose-fibre insulation, l og

homes, and prefabricated timber houses.

Comprehensive service concept

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 i s

accompanied by a customer-specific investmentstudy, 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

[email protected]

www.makron.fi

Makron’s cellulose-insulation technology

provides a turnkey solution for manufacturing

cellulose insulation from recycled newsprint, with

all of the necessary equipment and ser vices. The

delivery provides all the machiner y, 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 ar e

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 (H3BO

3 )

• 50–100 kg borax decahydrate (Na2B

4O

7*10H

2O),

or borax pentahydrate (Na2B

4O

7*5H

2O)

• 70 paper or plastic bags for packaging

Green TechnologyFibretec Production Lines

Walls

Density of 30–35 kg/m3 Exterior and interior walls

(spray-on method)

Density of 40–50 kg/m3

Vertical cavities(dry-blowing method)

Floors


Ceilings


Attics


Cellulose Insulation Technology Fibretec Production Lines

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