1. Ensure the interior of the puffing machine is clean and free from any debris before starting operations. A clean machine ensures smooth processing and prevents contamination of the final product.
2. Check that the tapered piston is positioned at its farthest point, allowing the discharge opening to be as wide as possible. This helps in achieving better material flow during the initial phase of operation.
3. Open the steam injection valve with a pressure set between 0.2 to 0.3 MPa to preheat the puffing barrel until the internal temperature exceeds 60°C. Proper preheating is essential for effective expansion and processing of the feed materials.
4. After preheating, close the steam injection valve and start the main motor. This step initiates the mechanical process within the extruder, preparing it for feeding and processing.
5. Begin feeding the raw material into the puffing barrel through the feed auger. Then, open the steam injection valve and adjust the tapered plug to ensure the production of high-quality expanded products.
6. Once the desired output is achieved, avoid making arbitrary changes to the dry material or steam input. Keep the motor load stable and allow the barrel temperature to reach equilibrium, typically after about 15 to 20 minutes of operation.
7. The ideal temperature range for the cylinder is usually between 105°C and 115°C. Adjust the steam and production rate accordingly to achieve the best porous structure and quality of the final product.
8. Gradually increase the steam supply as needed to maintain product quality while ensuring the main motor does not exceed its rated current. This balance is crucial for both product consistency and equipment longevity.
9. During daily or continuous operations, ensure that the material feed is consistent and stable. Uniformity in feed composition, particle size, moisture content, and temperature is vital for maintaining steady extrusion performance.
10. Steam should enter the extruder directly through the injection valve, mixing with the material inside the barrel. Maintain a stable steam pressure, typically between 0.6 to 0.75 MPa, to ensure efficient processing.
11. The steam flow control is managed manually via the steam injection valve. The degree of valve opening is determined by the number of revolutions during the startup phase, which affects the initial steam distribution.
12. Motor power consumption depends on how much force is required to push the material through the extruder. To increase motor load, you can:
A. Increase the amount of feed material.
B. Reduce the gap of the tapered plug at the discharge port.
C. Operate under low humidity conditions, which can increase resistance and thus the motor load.
13. The puffing temperature can be increased through friction generated by the rotating shaft and the injected steam. You can raise the temperature by:
A. Injecting more steam into the system.
B. Reducing the gap of the tapered plug at the discharge port.
14. Operating the hydraulic tapered plug involves the following steps:
A. At startup, the tapered plug should be fully retracted, creating the largest discharge opening.
B. After the main motor starts, begin feeding the material into the puffing barrel. Open the steam valve, activate the hydraulic system, and adjust the tapered plug manually. Monitor the material thickness and motor current to meet the required standards. The motor current is inversely proportional to the taper plug opening. Once adjusted, stop the hydraulic motor and return the reversing valve to the neutral position.
C. Throughout the production process, continuously adjust the tapered plug according to the material flow, using the same method as described in B.
D. For shutdown procedures: first, close the feeding inlet, open the tapered plug, and turn off the steam. Allow all remaining material to be expelled from the puffing cylinder. Cut off the hydraulic system power and then turn off the main motor. Stop feeding once the conveyor has stopped, and let the extruder vent any residual material. Retract the tapered plug to its maximum position for safe storage.
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