Foam Insulation Board Extrusion (XPS Extrusion) Lines

Sunwell Global is a leading manufacturer of XPS foam board extrusion lines, providing advanced and reliable solutions for high-quality insulation board production. Our tandem XPS extrusion systems are engineered for stable, continuous operation and utilize CO₂ as a blowing agent to support environmentally responsible and energy-efficient manufacturing.

High Production Capacity and Dimensional Flexibility
Sunwell XPS extrusion lines offer output capacities from approximately 250 to 1,200 kg/hr, producing boards with thicknesses from 20 mm to 200 mm and widths from 600 mm to 1,200 mm. This wide production range allows manufacturers to meet diverse insulation market requirements.

Automated Raw Material Handling and Blending
The system supports automatic handling and precise blending of up to eight raw materials, including flame retardants and nucleating agents. This ensures a homogeneous melt and consistent foam structure in the primary XPS extruder.

Precise Blowing Agent Metering and Control
CO₂, plasticizers, and optional HFC blowing agents are accurately metered using ATEX-compliant, triple-head diaphragm pumps with mass flow measurement, ensuring stable foam density, uniform cell structure, and superior board quality.

Advanced Tandem Extrusion Technology
The secondary XPS extruder is equipped with a high-mixing, low-shear screw, a water-cooled bimetallic barrel, and motorized valve control to minimize temperature fluctuations. A static mixer and homogenizing tube ensure melt uniformity before entering the chrome-plated flat XPS die, which features quick-opening capability, fine-adjustment bolts, and Teflon guide shoes for precise board formation.

Efficient Calibration, Cooling, and Cutting Systems
The board calibration unit uses temperature-controlled plates and a heavy-duty haul-off system designed to withstand CO₂ expansion pressure. A fail-safe pneumatic quick-opening mechanism enhances operational safety. Cooling conveyors allow controlled board stabilization before edge milling and precise length cutting by a high-speed double-blade cross cutter.

Flexible Surface Finishing and Edge Profiling
Boards can be planed or grooved to meet specific insulation market requirements. Edge profiles such as flat, tongue-and-groove, or shiplap can be produced after additional cooling and milling.

Fully Automated Stacking and Packaging Solutions
Sunwell provides fully automatic board stacking and six-sided wrapping systems, with optional add-ons such as in-line product printing, soundproofing, and dust extraction—delivering a complete, turnkey XPS insulation board production solution.