Cellulose Insulation Technology Fibretec Production Lines Succeed with Green technology - Convert newsprint into greenbacks! ENG Fibretec 1000 Fibretec 1000 is an economical system for starting cellulose insulation manufacturing business. It consists of a basic set-up of high quality equipment optimized for 1000 kg/hour capacity. Manually operated paper feeding and insulation packaging systems are easy to use and control. In this case, the recycled paper comes to the factory in loose form. Pre-crushing is performed by a sturdy Hammermill. Final refining is performed by the powerful 30” Fiberizer, which refines the paper into very fluffy insulation with the best coverage and lowest settled density. At the end of the line, the insulation is packed in paper sacks using the screw driven Packaging Unit. Dust collection takes place effectively by separating process air from the material flow by the Cyclone Separators and by leading the air through the self-cleaning Dust Filter Unit. As an option, the system can be equipped with a Paper Shredder, which makes it possible to use compressed paper bales as raw material. With the Paper Shredder the process also becomes a 3-stage process, which further improves the coverage and lowers the settled density of the installed insulation. A Chemical Pulverizer for improved fire retardant properties of the chemical additives, as well as a Spark Detection & Extinguishing System for improved safety of the plant are also available as optional items. Example layout 1. 2. 3. Pre-handling Table Feeding Conveyor Paper Shredder (Option) Hammermill Trash Separator Blower 1 Cyclone Separator 1 Paper Surge Bin Feeding Device for Chemical Additive 1 Chemical Additive 2 Pulverizer (Option) 12. Chemical Blower 13. Blower 2 14. Fiberizer Model 30” 15. Blower 3 16. Cyclone Separator 2 17. Packaging Unit 18. Pressing Belt 4. 5. 6. 7. 8. 9. Conveyor 19. Weighing Conveyor 20. Dust Filter Unit 21. Piping 22. Spark Detection 10. Feeding Device for 11. Chemical & Extinguishing System (Option) System 23. Electric Control 1. 4. 7. 16. 8. 9. 10. 11. 20. 22. 7. 23. 6. 5. 4. 8 21. Technical Data Effective capacity: 1000 kg/h x 16 h/day ~ 12800 kg / day (with 80 % work time efficiency) 16. 14. Required space: ~ 300 m2 + ~ 300 m2 for storing the raw material and final product. Free height of the hall: min. 8000 mm 15. 17 2. 3. 12. 11. 13. Power supply: Voltage: 400/230 V, 50 Hz Connected power ~ 220 kW (without optional items) 18. 1. 9. 10. 19. Compressed air supply: Pressure Min 0,6 MPa - Max 0,7 MPa Quantity ~ 600 l/min Water supply (only with optional item 22): Pressure Min 0,2 MPa – Max 0,6 MPa Operators: 3 persons per shift 1000 kg/hour ~70 bags/hour 14. 17. 18. 19. 20. Auxiliary equipment: 1 fork lift 1- 2 hand pallet trucks Paper sack information Size of filled sack: 1200 x 500 x 220 mm (H x W x T) Weight of filled sack: 13 - 15 kg (adjustable) Fibretec 1800 Fibretec 1800 includes the complete set of equipment for manufacturing cellulose insulation up to 1800 kg per hour. The basic version is equipped with devices for using loose paper as raw material, and paper feeding to the process takes place manually. This enables the use of recycled paper collected from the households or the use of overnight unread newsprint from the printhouses. Pre-crushing is performed by a sturdy Hammermill. Final refining is performed by the powerful 42” Fiberizer, which refines the paper into very fluffy insulation with the best coverage and lowest settled density. Dosing of the chemical additives takes place by the very accurate dosing units which are equipped with weighing sensors and hoists for handling 1000 kg chemical sacks. Packaging of the insulation is performed by the fully automated Hydraulic Baler & Bag Form, Fill and Seal Unit. Dust collection takes place effectively by separating the process air from the material flow by the Cyclone Separators and by leading the air through the selfcleaning Dust Filter Unit. As an option, the system can be equipped with a Paper Shredder, which makes it possible to use compressed paper bales as raw material. With the Paper Shredder the process also becomes a 3-stage process, which further improves the coverage and lowers the settled density of the installed insulation. A Chemical Pulverizer for improved fire retardant properties of the chemical additives, as well as the Spark Detection & Extinguishing System for improved safety of the plant are also available as optional items. Example layout 1. 2. 3. Pre-handling Table Feeding Conveyor Paper Shredder (Option) Hammermill Trash Separator Blower 1 Cyclone Separator 1 Paper Surge Bin Dosing Device for Chemical Additive 1 Chemical Additive 2 (Option) 12. Chemical Blower 13. Blower 2 14. Fiberizer Model 42” 15. Blower 3 16. Cyclone Separator 2 17. Hydraulic Baler 4. 5. 6. 7. 8. 9. & Bag Form, Fill and Seal Unit 18. Belt Conveyor 19. Dust Filter Unit 20. Piping 21. Spark Detection 10. Dosing Device for 11. Chemical Pulverizer & Extinguishing System (Option) System 22. Electric Control 1. 2. 4. 7. 16. 8. 9. 10. 11. 19. 20. 21. 16. 7. 22. Technical Data Effective capacity: 1800 kg/h x 16 h/day~ 23040 kg / day (with 80 % work time efficiency) 6. 5. 8. 4. 13. 12. 11. 1. 9. 10. 18. 15. 14. Required space: ~ 400 m2 + ~ 400 m2 for storing the raw material and final product. Free height of the hall: min. 9000 mm 3. 2. 17. Power supply: Voltage: 400/230 V, 50 Hz Connected power ~ 415 kW (without optional items) Compressed air supply: Pressure Min 0,6 MPa - Max 0,7 MPa Quantity ~ 600 l/min Water supply (only with optional item 21): Pressure Min 0,2 MPa – Max 0,6 MPa Operators: 2- 3 persons per shift Other equipment: 1 fork lift 1- 2 hand pallet trucks 1800 kg/hour ~130 bags/hour 14. 17. 17. 19. 22. Packaging Plastic foil: width of foil roll 1450 mm foil thickness 70 – 110 µm Size of finished bag: length 790 mm (adjustable) width 390 mm thickness 325 mm weight 13 - 15 kg (adjustable) accuracy +/- 0,1 kg Fibretec 4000 Fibretec 4000 represents the highest level of technology in cellulose insulation manufacturing industry. The capacity 4000 kg per hour can be produced with only one key operator. The insulation is processed from the paper through our effective 3-stage process. Braking of the complete paper bales and the pre-crushing is performed by the un-manned Shredder. In the second stage the shredded paper is crushed by a sturdy Hammermill. Final refining is performed by the powerful 54” Fiberizer, which refines the paper into very fluffy insulation with the best coverage and lowest settled density. Both the paper and the chemical additives are precisely dosed and continuously weighed before they are mixed together, to ensure the exact mix ratio and to control the consumption of the costly chemical additives. Packaging of the insulation is performed by the fully automated Hydraulic Baler & Bag Form, Fill and Seal Unit. Dust collection takes place effectively by separating the process air from the material flow by the Cyclone Separators and by leading the air through the self-cleaning Dust Filter Unit. The system is also equipped with a Spark Detection & Extinguishing System for improved safety of the plant. As an option, the system can be equipped with a Chemical Pulverizer for improving the fire retardant properties of the chemical additives. 1. 2. 4. 7. 9. 10. 11. Example layout 1. 2. 3. 4. 5. 6. 7. 8. Bale Conveyor Shredder Hammermill Trash Separator Blower 1 12. Chemical Blower 13. Blower 2 14. Fiberizer Model 54” 15. Blower 3 16. Cyclone Separator 2 Cyclone Separator 1 17. Hydraulic Baler & Bag Form, Fill and Seal Unit Paper Surge Bin Paper Weighing Conveyor Dosing Device for Chemical Additive 1 Chemical Additive 2 (Option) 18. Belt Conveyor 19. Dust Filter Unit 20. Piping 21. Spark Detection 9. 10. Dosing Device for 11. Chemical Pulverizer & Extinguishing System System 22. Electric Control 14. 1. 19. 20. 21. 22. 16. Technical Data Effective capacity: 4000 kg/h x 16 h/day~ 51200 kg / day (with 80 % work time efficiency) 2. 9. 10. 11. 13. 12. 8. 6. 3. 4. 14. Required space: ~ 500 m2 + ~ 600 m2 for storing the raw material and final product. Free height of the hall: min. 9000 mm Power supply: Voltage: 400/230 V, 50 Hz Connected power ~ 545 kW (without optional items) 17. 5. 7. 15. Compressed air supply: Pressure Min 0,6 MPa - Max 0,7 MPa Quantity ~ 600 l/min Water supply (only with optional item 21): Pressure Min 0,2 MPa – Max 0,6 MPa 18. Operators: 1 - 2 persons per shift Other equipment: 1 fork lift 1- 2 hand pallet trucks 4000 kg/hour ~290 bags/hour 17. 17. 19. 22. Packaging Plastic foil: width of foil roll 1450 mm foil thickness 70 – 110 µm Size of finished bag: length 790 mm (adjustable) width 390 mm thickness 325 mm weight 13 - 15 kg (adjustable) accuracy +/- 0,1 kg Green Technology Fibretec Production Lines Makron Cellulose Insulation Technology provides a turnkey package of equipment and services for manufacturing cellulose insulation from recycled newsprint. The Makron supply includes all the machinery, piping, cables as well as the electric control system needed for the processing plant. The services include supervision for installation and start-up and also training of the customer’s personnel. Furthermore, Makron can assist the customer in many questions related to the end product know-how. Combined experience and know-how Since 2010 Makron has had a strategic alliance with Reynolds Engineering & Equipment, Inc., based in Muscatine, Iowa, USA. Reynolds is the leading manufacturer in North America of Fiberizers, Chemical Pulverizers and other equipment for the production of cellulose insulation. Today , the technology of the Makron supply is based on the combined know-how of both of these experienced companies. WALLS: • Density 30 - 35 kg/m3 Exterior and interior walls (spray on method) FLOORS: • Density 30 - 40 kg/m3 ATTICKS: • Density 25 - 30 kg/m3 CEILINGS: • Density 40 - 50 kg/m3 The following amounts of raw materials are needed for producing 1000 kg cellulose fibre insulation, approx.: • 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 • Density 40 - 50 kg/m3 Vertical hollows (dry blowing method) Why Cellulose Insulation? Convert a House into a Carbon Sink! Properties of Cellulose Insulation • Ecological – significantly lower embodied energy than in fiberglass or rockwool insulation • Self sealing insulation material, minimizes unwanted air leaks • Excellent thermal insulation value • Excellent acoustic properties, too • Breathing material – evens out the moisture in the structures • Fire safe – does not catch, propagate or spread fire • Resists rot, fungi growth and pests • Strong adhesion to the surrounding structures • Manufactured locally from recycled paper • User friendly installation – safe, no cutting, no waste Use of Cellulose Insulation The usual installation methods of cellulose insulation are blowing and spraying, therefore the result is a seamless insulation that fills perfectly the entire cavity. Blowing and spraying methods in installation ensure that the adhesion of the insulation to the structures will remain unchanged over the years. Cellulose fibre insulation can be installed manually or with specialised blowing or spraying machines. Due to the convenient installation method no cutting of the insulation material is needed. Blowing method is commonly used on horizontal and diagonal structures, e.g. on attics and floors, and on closed walls. The dry insulation material is blown into the cavity in question. The fine graded material penetrates well even the small holes and fills exactly and seamlessly the entire cavity. Spraying method can be used on vertical structures,e.g. on walls. The insulation material is moistened with fine water dust while it is sprayed onto the open structure. A seamless and draughtfree insulation layer is achieved even in narrow and complicated places. After drying the insulation is well adhered to the surrounding structures, which prevents separation from the structures. Demand for Sustainable Building Products is Increasing With cellulose fibre insulation it is possible to convert a house into a carbon sink. Cellulose insulation is an ecological and economical thermal and acoustic insulation material, for both new and renovated buildings. 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 determined and approved by local authorities) • Fire endurance: Cellulose fibre does not maintain or spread fire. (Actual classification according to local requirements) • Air conductivity 80…120 x 10-6 m3/msPa, depending on the installed density Better Technologies to Build Better Makron Technology from Finland Makron Engineering is well known as a reliable and competitive supplier of manufacturing solutions to the timber house and insulation industry. Today Makron supplies technology and equipment for manufacturers of cellulose fibre insulation, log homes and prefabricated timber houses. The premises of Makron Engineering are located in Lahti, Finland. Total Tervice Concept Makron experts provide the customers with the total service concept that covers design, machine manufacture, supplies, installation and start-up, training and maintenance. A guideline to our service is an investment study, which targets to improve our customer’s competitiveness, production capacity and quality. Contact Makron Experts and Succeed with Green Technology Makron Engineering Oy P .O.Box 104 (Norokatu 5) FI-15101 LAHTI, FINLAND Tel. +358 3 812 312 Fax +358 3 733 1299
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