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Product Description
This production line is engineered to produce high-quality plastic MBBR (Moving Bed Biofilm Reactor) biological filter media and fluidized-bed packing. It is optimized for thermoplastic resins such as PE, PP, ABS and HDPE, delivering stable, uniform biofilm carriers used in wastewater treatment, aquaculture and water reuse systems. The line combines reliable feeding & drying, precision single-screw extrusion, vacuum sizing/calibration and high-speed cutting to produce consistent parts ready for cleaning, inspection and packaging.
Suitable resin: HDPE (also PE, PP, ABS)
Line speed: 0.1 – 8 m/min (adjustable to product / mold)
Typical output: 80 – 100 kg/h (dependent on model & geometry)
Main motor power: 22 kW (standard example)
Power supply: 380 V, 50 Hz, 3-phase
Delivery time: ~30 working days (standard lead time)
Center height: 1000 ± 50 mm
Standard equipment list: vacuum loader, hopper dryer, SJ65/28 single-screw extruder, PE moulds, water cooling tank (vacuum calibrator), haul-off machine, flying-blade cutter, spare parts.
Automatic suction (vacuum loader) → 2. Hopper dryer → 3. Single screw extruder → 4. Die / mould → 5. Stainless-steel vacuum sizing & calibrating tank (water cooling) → 6. Haul-off & tensioning → 7. Flying-knife cutting → 8. Final inspection & packing.
Vacuum loader / hopper dryer: ensures dry, contamination-free feed for stable extrusion and minimized defects.
SJ65/28 single-screw extruder: accurate melting/plasticizing; forced water cooling at feed throat prevents bridging and slipping.
Precision die & stainless vacuum calibrator: vacuum sizing tank with tempered glass cover for observation; delivers dimensional accuracy and smooth surface finish.
Haul-off & flying-knife cutter: stable traction and high-speed cutting for uniform parts.
Control & sensors: Omron temperature controllers, Delta frequency converters, optional Siemens servos and Dynisco pressure/temperature sensors for closed-loop process control (PID/PLC).
Consistent product quality — vacuum sizing + calibrated water cooling yields stable geometry and smooth surface ideal for biofilm attachment.
Energy efficient & precise control — Omron controllers and Delta inverters reduce power use and enable precise zone temperature control. Optional PLC + PID intelligent adjustment improves repeatability.
Robust mechanical design — screw & barrel made of high-strength nitrided alloy (precision polished) for extended life and better plasticization.
Low risk of blockages — feed area forcibly cooled by water prevents material slipping or clogging at the throat.
Flexible cooling options — choose immersion tank, vacuum tank, spray tank or combination to match product shape and production speed.
Operator friendly & serviceable — tempered glass sink cover for visual monitoring, easy access for maintenance; optional alarm & real-time detection features.
Turnkey line — supplied with moulds and accessories, turnkey commissioning and operator training available.
MBBR biofilm carriers for municipal and industrial wastewater treatment
Fluidized bed packing media for biological reactors and aerated filters
Media for aquaculture biofiltration systems
Custom plastic packing used in water reuse and tertiary filtration systems
Values are indicative for the standard configuration shown in the datasheet. Actual parameters will vary by product geometry and customer specification.
Resin: HDPE (PE / PP / ABS optional)
Line speed: 0.1 – 8 m/min
Output: 80 – 100 kg/h
Main motor: 22 kW (example)
Power supply: 380 V / 50 Hz / 3-phase
Center height: 1000 ± 50 mm
Typical lead time: 30 working days
We supply full turnkey services: layout design, installation supervision, on-site commissioning, operator training and spare parts kits. Optional upgrades include PLC/HMI control, Siemens servos, Dynisco melt pressure sensors, and chillers / vacuum pumps for specific cooling strategies.
Q1 — Which resins can you process for MBBR media?
A1 — The standard line processes HDPE with optional compatibility for PE, PP and ABS. We recommend HDPE for most bio media due to its chemical resistance and density. Tell us your resin spec and we’ll confirm screw geometry and barrel treatment.
Q2 — How do you guarantee geometric accuracy and surface finish?
A2 — We use a stainless steel vacuum sizing/calibration tank and precision die heads. Temperature zones are PID-controlled and the vacuum sink prevents shrinkage, ensuring stable dimensions and smooth surfaces ideal for biofilm growth.
Q3 — What output can I expect for complex carrier shapes?
A3 — The quoted 80–100 kg/h is for standard geometries. Complex or large hollow shapes will reduce line speed and throughput. Send your part drawing and target capacity and we’ll provide a realistic output estimate.
Q4 — What control & instrumentation is included?
A4 — Standard: Omron temperature controllers and Delta frequency converters. Optional: Siemens servos, Dynisco melt pressure sensors, PLC/HMI with PID auto-tuning and real-time alarms for process stability.
Q5 — What cooling/vacuum options are available?
A5 — We offer immersion tanks, vacuum tanks, spray tanks and combination systems. Tempered glass covers allow visual monitoring. We can also supply vacuum pumps, water pumps and chillers to match the chosen cooling scheme.
Q6 — What maintenance and spare parts should I budget for?
A6 — Regular maintenance includes screw/barrel inspection, heater band checks, pump maintenance and cutter blade replacement. We supply a recommended spare parts kit and can provide annual service contracts.
