High-Precision Knife-Over-Roll Coating Line for XPS Foam Board Surface Levelling & Smoothing
Price:
Negotiation
MOQ:
1 Set
Delivery Time:
30~40 Days
Brand:
OSMANUV
Product Description
High-Precision Knife-Over-Roll Coating Line for XPS Foam Board Surface Levelling & Smoothing
Our High-Precision Knife-Over-Roll Coating Line is specially engineered for applying uniform cementitious, polymer, or acrylic coatings onto XPS foam boards. Using a rigid doctor blade precisely positioned above a precision-ground backing roller, the machine ensures exceptionally consistent coating thickness across the entire board width. The system effectively fills surface pores, hides foam texture, and creates a perfectly smooth, level base for exterior insulation finishing systems (EIFS), decorative renders, or protective layers.
Production Line Composition
| Module | Description |
|---|---|
| 1. Automatic Infeed Conveyor | Roller or belt conveyor with side guides for accurate XPS board positioning |
| 2. Surface Pre-Treatment Unit (Optional) | Corona, plasma, or flame treater to increase surface energy for better coating adhesion |
| 3. Knife-Over-Roll Coating Station | Precision doctor blade assembly with adjustable gap and high-accuracy backing roller |
| 4. Coating Material Supply System | Pump and circulation system with viscosity control and filtration |
| 5. Leveling & Drying Conveyor Section | Multi-zone hot air or IR drying tunnel for rapid curing |
| 6. Cooling Zone | Forced ambient air cooling to stabilize the coated board |
| 7. Automatic Stacking/Unloading Unit | Pneumatic or servo-driven stacker for finished panels |
| 8. Central Control Cabinet with HMI | PLC-based system with touchscreen for parameter setting, recipe storage, and real-time monitoring |
Technical Specifications
| Category | Parameter | Specification / Description |
|---|---|---|
| Workpiece Dimensions | Max. Board Width | Customizable (Standard: 600mm, 1200mm, 1350mm) |
| Board Length | Unlimited (continuous process) | |
| Board Thickness Range | 10 - 200 mm (adjustable roller gap) | |
| Coating Parameters | Coating Method | Knife-over-roll (doctor blade) |
| Coating Thickness (Wet) | Customizable from 0.5 mm to 10 mm (stepless adjustment via micrometer) | |
| Coating Thickness Tolerance | ±0.1 mm across the entire width | |
| Coating Material Viscosity | Suitable for low to high viscosity (100 - 100,000 cP) | |
| Mechanical Specs | Blade Material | Hardened stainless steel or tungsten carbide tip (optional) |
| Backing Roller Diameter | Ø200 - Ø300 mm, precision-ground, chrome-plated | |
| Conveyor Speed | 1 - 20 m/min (frequency inverter controlled) | |
| Drying Section | Drying Method | Hot air circulation (gas or electric heating) |
| Drying Temperature Range | Ambient - 150°C (zone control) | |
| Tunnel Length | Customizable (Standard: 6m, 8m, 12m) | |
| Utility & Safety | Power Supply | 380V / 415V, 3-phase, 50/60Hz (customizable) |
| Compressed Air | 6-8 bar, dry and clean | |
| Safety Features | Emergency stop, overload protection, safety guards | |
| Control | HMI | 7-inch or 10-inch color touchscreen, recipe storage, data logging |
Applications
- External wall insulation boards (EIFS) - applying base coat or adhesive mortar onto XPS
- Decorative XPS panels - coating with colored acrylic renders or textured finishes
- Industrial foam components - adding anti-static, fire-retardant, or protective coatings
- Underlayment for flooring - smoothing the surface of XPS underfloor heating boards
- Roof insulation panels - applying weather-resistant topcoats
Customization Options
- Board Width & Tooling - Coating width customizable from 300 mm up to 2400 mm
- Coating Thickness Range - Doctor blade gap mechanism customizable for 0.2 mm to 15 mm wet films
- Blade Type - Options include flexible steel blade, rigid square-edge blade, or adjustable two-blade scraper system
- Drying Tunnel Configuration - Customizable length, zones, heating method, and cooling section
- Integration - Customizable connection with upstream XPS extrusion lines or downstream equipment
- Material Supply - Automatic feeding system with agitator, gear pump, or screw pump based on viscosity
Key Features
- Superior Surface Quality - Eliminates marks, streaks, and air bubbles for perfectly flat coating
- Wide Thickness Adjustability - Micrometer-controlled blade gap allows instant thickness changes
- High Material Efficiency - Minimal material waste compared to spray or curtain coating
- Robust Industrial Construction - Heavy-duty steel frame, corrosion-resistant surfaces for 24/7 operation
- Easy Cleanup & Maintenance - Quick-release blade assembly and accessible coating trough
- Energy-Efficient Drying - Multi-zone hot air recycling with heat recovery option
Support and Services
- Pre-Sales Engineering - Free layout design, line simulation, and coating feasibility testing
- Installation & Commissioning - On-site setup and fine-tuning by senior engineers
- Training - Comprehensive training for operators and maintenance personnel
- Warranty - 18 months on main machine, 12 months on electrical parts
- After-Sales Support - Lifetime technical consultation, spare parts supply, and remote diagnostics
Packing and Shipping
- Packing - Modules disassembled, wrapped in anti-rust oil, sealed with stretch film, packed in export-grade plywood crates
- Marking - Clear shipping marks, lifting points, and fragile labels
- Shipping - Sea freight (FOB, CIF, EXW terms) or air freight for urgent orders with full customs documentation
- Lead Time - Standard customized models: 10-12 weeks after order confirmation
Frequently Asked Questions
What types of coating materials can this line apply onto XPS?
It works perfectly with cementitious mortars (EIFS base coat), acrylic renders, polymer-modified adhesives, gypsum-based plasters, and flame-retardant paints. The material viscosity range is broad, and the pump system can be customized accordingly.
Does the line damage the soft XPS foam surface?
No. The backing roller is soft (rubber-coated or polyurethane) to protect the foam, while the doctor blade only contacts the coating paste. The conveyor support also has low-pressure contact points.
How do you ensure consistent coating thickness across the entire board width?
The precision-ground backing roller, combined with a rigid blade holder and micrometer adjustment at both ends, ensures linear blade flatness within ±0.05 mm across the full width. Automatic blade wear compensation (optional) further improves consistency.
Can this machine apply two layers in one pass?
A dual-head configuration (two scraper stations) can be customized to apply a second layer immediately after the first drying or semi-drying stage, saving space and handling time.
What is the typical drying time for a 3mm cementitious coating on XPS?
At 80°C with forced air circulation, drying takes approximately 10-15 minutes depending on moisture content. Our drying tunnel length can be customized to match your required line speed.
Do you offer a sample coating trial?
Yes. Send us your XPS boards and coating material, and we will run trials at our lab facility. We will provide coated samples, optimized process parameters, and a video report.
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Get in Touch
Have questions about our products or want to discuss a custom order? Our team is ready to help you.
Company
Dongguan Osmanuv Machinery Equipment Co., Ltd
Location
28 the second industrial, Liu chong wei , Wanjiang ,DongGuan , Guangdong, China
Contact Person
Zhang guoxin