The VihoX 120 PP/PS Single-Screw Sheet Extrusion Line (Equipped with Melt Metering Pump) is our high-precision single-screw configuration engineered for converters demanding the tightest possible sheet gauge tolerance. While sharing the heavy-duty Φ120 mm single screw (32–35:1 L/D ratio) and 90–132 kW high-torque drive of our standard 120 model, this upgraded system incorporates an integrated 250CC precision gear melt pump positioned directly between the hydraulic screen changer and the T-die manifold.
Operating at outputs of 250 to 350 kg/h across finished sheet widths from 650 to 850 mm and calipers between 0.3 mm and 2.0 mm, the melt pump completely decouples extruder screw pressure fluctuations from the die lips. In combination with an independently driven vertical three-roller calender stack (Φ400–500 mm), this line reduces cross-web and machine-direction thickness variations to ±0.01 mm, drastically reducing reject rates on automated high-speed cup making and packaging lines.
Factory trial run: VihoX 120 PP/PS Single-Screw Sheet Line with Metering Pump Running Test
| Specification Item | Engineering Value | Operational Relevance |
|---|---|---|
| Suitable Resins | PP / PS / HIPS / PE | Precision sheet for high-speed multi-cavity thermoforming molds |
| Screw Diameter & Type | Φ120 mm Single Screw | Bimetallic barrel with wear-resistant flight metallurgy |
| Length-to-Diameter Ratio | 32–35:1 L/D | Long melting zone generating homogeneous melt pool for the gear pump |
| Sheet Structure | Single Layer | Ideal for premium high-clarity PP/PS drinking cups and lid stock |
| Finished Sheet Width | 650 – 850 mm (Customizable) | Standard width range tailored for VihoX-720 and VihoX-750 cup machines |
| Sheet Thickness Range | 0.3 – 2.0 mm | Maintains tight gauge tolerance even at high speeds and thin calipers |
| Reference Hourly Output | 250 – 350 kg/h | Consistent volumetric throughput under varying regrind percentages |
| Main Motor Power | 90 – 132 kW | High-efficiency AC drive maintaining steady extruder barrel feeding |
| Total Installed Power | Approx. 160 – 190 kW | Includes heating zones, melt pump servo drive, and calender motors |
| Calender Roller Dimensions | Approx. Φ400 – 500 mm | Super-mirror chrome finish with internal spiral cooling flow |
| T-Die Lip Width | 800 – 1000 mm | Coat-hanger extrusion die with differential manual lip adjustment bolts |
| Production Line Speed | Approx. 10 – 30 m/min | Stable web speed synchronized with melt pump rotational rate |
| Roller Cooling Architecture | Circulating Water Cooling (Tower/Chiller) | Closed-loop water circulation with digital temperature control units |
| Roller Drive Mechanism | Independent Motor Drive | Each calender roll powered by its own servo motor for fine speed ratio tuning |
| Melt Metering Pump | 250CC Precision Melt Gear Pump | Absorbs screw surging, guarantees constant volumetric melt delivery to die |
| Winding Configuration | Two-Station Winding Unit | Dual cantilever winding shafts with pneumatic slip core tension control |
| Electrical Utility Standard | 380V / 50Hz / 3-Phase | Configurable for 220V, 415V, or 480V industrial grid systems |
| Footprint Envelope | Approx. 12 × 2.0 × 2.2 m | Straight inline arrangement providing generous operator working room |
| Machine Weight | Approx. 8 – 13 Metric Tons | Heavy structural foundation preventing vibration propagation to T-die |
In standard extrusion, screw flight rotation and temperature cycles inevitably create small pressure pulses (typically ±3% to ±5% at the die). These variations translate directly into longitudinal sheet thickness waves. For high-speed cup making machines cycling at 30+ cycles/min, uneven sheet thickness causes uneven sidewall stretching, lip curling defects, and product weight scatter. The integrated 250CC gear pump acts as a positive displacement barrier: it absorbs upstream extruder pulsations and discharges polymer melt at an unyielding, constant volumetric flow rate, tightening thickness tolerance to an extraordinary ±0.01 mm.
By delegating the task of building high die pressure (10–15 MPa) to the dedicated gear pump, the main extruder screw can operate at significantly lower back pressures. This reduces shear heat, lowers melt temperatures by 10°C–15°C, preserves polymer molecular weight chains, and cuts specific electrical consumption per kilogram of extruded sheet. Barrel and screw wear are substantially reduced, leading to longer service intervals and fewer maintenance stoppages.
This high-precision configuration is specially recommended for facilities focusing on high-speed premium packaging:
The 250CC melt pump isolates extruder pulsation, delivering uniform volumetric flow that tightens sheet thickness tolerance to ±0.01 mm. This eliminates cup weight variation and prevents thermoforming web jams.
A digital melt pressure transducer positioned before the pump feeds real-time signals to the extruder inverter, automatically modulating screw speed to maintain constant inlet pressure.
Yes. Our melt pumps feature nitrided and hardened alloy steel gears and ceramic-coated bushings, providing long wear life even with 40% CaCO3 filled masterbatch blends.
A continuous hydraulic screen changer precedes the melt pump, ensuring all polymer melt is filtered through 80–120 mesh screens before entering the precision gear cavity.
The pump uses polymer-lubricated internal journal bearings that require zero external grease. Routine operation only requires standard purging during resin color changes.
Each of the three calender rollers is coupled directly to an AC servo gear motor managed by the master PLC touchscreen, allowing micro-draw ratios to be programmed effortlessly.
A standard 380V/50Hz 3-phase factory line with a 250 kVA transformer easily supports the 160–190 kW installed load, with typical running power consumption averaging 95–120 kW.
VihoX provides complete English operating manuals, electrical ladder diagrams, foundation layout CAD files, spare parts kits, and on-site engineering commissioning worldwide.
Learn how closed-loop melt pump pressure regulation cuts web thickness variance to 0.01 mm for high-speed automated forming molds.
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