AKKAYA EPS Makina Imalat Sanayi ve Ticaret A.S.

Piri Mehmet Pasa Mah. Baskomutan Cad., New Center AVM No: 106 , 34570 Silivri Istanbul
Turkey

Telephone +90 282 6911275
Fax +90 282 6911278
info@akkaya-akkaya.com

This company is main exhibitor of

Trade fair hall

  • Hall 13 / D47
 Interactive Plan

Hall map

K 2016 hall map (Hall 13): stand D47

Fairground map

K 2016 fairground map: Hall 13

Our range of products

Product categories

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.02  Machinery and plant for processing
  • 03.02.005  Machinery for foam and reactive resins
  • 03.02.005.01  Preexpanders, foaming machinery for parts and blocks (for EPS, EPP, EPE)

Our products

Product category: Preexpanders, foaming machinery for parts and blocks (for EPS, EPP, EPE)

EPS Block Moulding Machine

Basic Body

Blockmould is designed in vertical sahpe, with only one side openning which ensures the steam and vacuum tigthness 100% during the process. This is also needed for the pressure sertification and during operation machine needs less service. Predefined dimensions on the blockmould and working pressure indictes that the unit is a kind of pressure vessel (box) which has to be made from special material, afterwards verified by an inspector. (TUV-BureuVeritas) The certificates for inpection will be delivered together with the machine and this protects the buyer and the seller from the future problems against labour issiues.

The machine is made with fix walls, according to the demand we can also offer adjustable walls. Machine steam chamber made of stainless steel wedge wires (SSWW) means has an openning surface of steaming 12%. This accelerates the steam and vacuum cycles and in the end cycle time shortens. The plates connected with 6 screws, easy to service when needed.

Filling Silo

Filling silo located behind the machine, level is controlled by level sensors automatically. The unit stops the machine when there is not sufficient material avaliable in the silo. Includes all the piping material pipies diameter 250 mm, from the silo till filling injector on the top of the machine. There is a slide under the silo which allows to take the raw material back to the silos when needed via transfer fan. Optionally filling silo can be equipped with a filter inside and an exit on the side of the silo to collect the dust in a plastic bag.

Vacuum Unit

With the help of the vacuum, machine has a homogenous fusion inside the block and it helps to reduce the cycle time. The water which is accumulated in the vacuum system evacuated without water pumps-means that it brings advantage on the electrical consumption. Cylindrical vacuum tank, vertically positioned next to blockmould steam/water condenser.

Material Unloading Conveyor

Unit equipped with an electronic scale, measures the weigth of the blocks which comes out from the block mould. It moves together with the door of the machine and located 90⁰ against the exit side of the mcahine. Blocks are moved on a stainless steel chain and if needed datas can be printed on the block during this time via inkjet printer.

Block Elevator

After the unloading conveyor, block needed to be transported to storage. This unit brings the blocks down to floor with hydraulic movement to be transproted with a simple transpallet operated by a person. Unit has a housing which let the transpallets to go under the block easily. Delivered together with a roller conveyor with a 3 pieces block capacity.

Control panel

Main cabinet with security lock main swicth PLC SIEMENS S7 serie Touch screen panel size 10.1”, operator friendly functions, showing the process operations with simulation Production datas can be stored as Receipe on the panel or can be transferred, loaded any time needed. Showing the steam and foam pressure diagram enables to follow the process steps easily.

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Product category: Preexpanders, foaming machinery for parts and blocks (for EPS, EPP, EPE)

EPS Cutting Line

Basic Body

AKKAYA EPS cutting line, equipped with oscillating cutting, rigid body, precise cutting properties. Modular system enables the line for upgrade whenever necessary, operator friendly control system for large productions.

Special designed hot wire oscillation, has an automatic speed control system during cutting. This gives the change for fast cutting without any wire break. This option installed only on horizontal cutting station.

With long stroke oscillation and adjustable oscillation speed guarantees the fastest cutting speed at all time with a smooth surface.

PLC control system SIEMENS S7-including 15’’ touch color display enables the operator to watch all the process parameters during cutting. Recipe and production parameters can be stored, recall or moved to any place via memory stick on the PLC or network.

Horizontal cutting unit equipped with wire break system, which stops the cutting for broken wire.

Block Loading Unit

System can be placed 90º with the suitable location for the cutting line direction or in line. The blocks are positioned by operator using the forklift, the roller conveyor has a suitable inlet. When the tilting unit is free each block, moved to tilting unit for start cutting stage. Total length of the unit enables to load up to 5 blocks.

Block Tilting Unit

Block Tilting Unit to feed the cutting line with hydraulically operated platform. The blocks come to the beginning of the line, after centering operation made by pneumatic pushers, the unit lays the block down on the horizontal cutting chain conveyor. The gap between the blocks are 35-40 cm. The block is sent to horizontal cutting unit.

Bottom and Side Scrap Recovery

With vacuum suction device located under the block, rest skin collected with a 1400 mm wide turning roller. The side scrap coming during the cutting, directed via the side cover cabin to under of the line with gravity. The pre-crusher positioned in the end of the coveyor recycles the scrap and send to recycling unit.

Top Scrap Recovery

Equipped with vacuum suction unit, the skin come out from the top of the blockmould collected via 1400 mm conveyor, then with chain drive directed to pre-crusher located on the top side of the cutting line. The pre-crushed material transferred through a fan to the recycling system.

Auto Wire Setting Unit

Horizontal cutting unit with oscillation has an automatic wire setting system with servo motors. The wires set very fast, to desired thickness. With the oscillation cutting, the material consumption is less, and smooth surface on the sheets. With the robot servo controlled, wires set to position and locked via pneumatic air lock. Wire setting unit can set 62 wires, less than 2 minutes. The total heigth of the unit is around 4 meters. The auto wire setting can be used for minimum 10 mm wire thickness without any human intervention This system equipped with AWP (auto wire protection) automatic cutting speed control. The blocks on the chain conveyor cut with maximum speed at all time, but when the wires start to get tension due to cutting speed, this system detecs the tension and slow the speed until the tensin is finished. The system operates with PID control, which increase and decrease the cutting speed when needed. This helps for the wires long life and better surface quality on the sheets.

Automatic De-stacking Unit

This unit can be used together with the auto wire setting option. After the vertical cutting stage, the packs come on the final motorized conveyor and prepared to enter the de-stacker. According to the wire thickness, the unit recognize the sheet thickness and quantity to adjust the rigth numbered eps packs. After the packs are done, via a motorized conveyor it is driven in the packing machine. The machine operates with two packs size.

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Product category: Preexpanders, foaming machinery for parts and blocks (for EPS, EPP, EPE)

EPS Tight Packing Machine

Basic Body

Stretch banding/sealing is a cost effective method to create a wrap of PE-film around the sheet bundles for easy handling, securing and adding information.

The sheet bundle is pushed into the machine and takes along a certain amount of film. During the process the film is stretched and sealed together. This results in a highly cost effective use of wrapping material.

The simple and reliable machine allows an operation in manual or automatic mode.

Capacity

4 pack/min (Pneumatic welding)
8 pack/min (Motorized welding)

Opetarion

Machine operation is simple and reliable
Wrapping the sheets on 4 sides by pushing them into stretched foil
Positioning and fastening of foil and package
Forming package by welding and cutting the foil.

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Product category: Preexpanders, foaming machinery for parts and blocks (for EPS, EPP, EPE)

Shape Moulding Machine For EPS & EPP Application

Quick Mould Change System

Shape Moulding with hi-tech process control with advantages like, fast mould change system with a clamping frame galvanized. Mould change within 15 minutes.

Roboust body with complete milling job is done with all parts.Guide bars 2-4 pieces according to the size of the machine.

Movement

Hydraulic system allows fast movemets with a soft action, or alternative Electrical drive even more faster action. All steam and air control is proportonally driven which creates energy saving and fast cycle times.

Equipped with fast mould change system
Proportional control for Steam & Air
De-loading and Stacking robot
Surface treatment mouldings
Electrical drive with knee lever.

Machine Components

Process Control Bachmann
PLC Pneumatic Control Festo
Hydraulic Drive Parker
Electrical Component Schneider
Process control Valves Gemü
Electrical Servo Drive Schneider
Gearbox Keb

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Product category: Preexpanders, foaming machinery for parts and blocks (for EPS, EPP, EPE)

EPS Batch Type Pre-Expander

Basic Body

Working principle of the batch type, to expand a fixed mass of raw material in a fixed volume which enables to reach easily desired density

Dosing Unit, to weigth the rigth amount of EPS for the adjusted density. Filling to the vessel is done by gravity.

Expansion chamber made of AISI 304 stainless steel, cylindrical shape.

Agitator and accessories made of AISI 304 stainless steel, speed control via drive. With the adjustable speed in different steaming phases, enables processing of different materials.

Discharge door located on the floor of the vessel, to empty the chamber fast.

Fluidized bed dryer, inside floor parts made of AISI 304 stainless steel, where the expanded material going out from the expansion chamber to dry the beads. The unit is equipped with a steam-air heat exchanger inside, which avoid the beads from thermal shock.

Material Transport unit, has a rotary valve system, to send the material to the silos.

Machine has a built-in silo control system, with the rigth hardware you can operate this part. Pre-expanded beads from the pre-expander conveyed to the storage silos for 1st and 2 nd expansion stages

After the pre-expansion, you can select the silo from the display, where you want to send the eapanded material. The operator can select several silos at the same time with a priority.

The system follows the selection after the order finishes the machine stops as well. For 2nd expansion, same selection steps are possible. From all the silos, you can make 2nd expansion process.

This conveying system named silo top distribution and all the operation controlled via pre-expander panel.

High Density processing: The air and steam adjustment can be done automatically, in quantity and temperature during all expansion stages. This unit helps to expand densities over 30 kg/m³ till 50 kg/m³. To be on the safe side, densities over 30 kg/m³ should be expand at lower volumes . To do that the levels sensors must be adjusted correctly.

Material Loading Hopper

Volume 1.25 m3 which is approximately 1.100 kg EPS capacity. Equipped with flexible hexagonal feeder.

Alternatively material loading hopper; Capacity 3+1 (Octabin) 1100 kg

2nd Expansion Unit

This unit is necessary to proces under 12 kg/m³ bulk density. The pre-loading silo is located on the top of the expansion chamber, with electronic scale system to control the proper filling for second expansion. The PLC calculates the necessary amount (kg) of material for second expansion, and expand in a fixed volume. The filling from the silo to the machine is done by a vacuum fan.

Machine Control Panel

Machine is controlled by SIEMENS S7 type PLC. Touch panel size 10.1” full color. With this display the operator can change process parameters, and recipes can be added, changed and saved in the PLC. Also can be transferred to any place.

Density Control Unit (Control-Adjust Density)

For checking the pre-expanded bulk density, via a sample material taken from the dryer. After each cycle, mateial taken from the dryer and weighed in fixed volume. The unit measures, and inspects the expansion values. Different measurements can be followed on the display. Production data can be saved or printed on a paper.

Material Transport Unit

Material Transport unit, has a rotary valve system, to send the material to the silos.

Fluidized Bed Dryer

Fluidized bed dryer, inside floor parts made of AISI 304 stainless steel, where the expanded material going out from the expansion chamber to dry the beads. The unit is equipped with a steam-air heat exchanger inside, which avoid the beads from thermal shock.

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About us

Company details

Since 1980 AKKAYA engines and manufactures machinery for processing expandable Polystyrene (EPS) Intensive exchange of experience with all our customers enabled the engineering of cost-efficient, highly productive, easy to maintain and user friendly machines and production lines - which are exported global since 1980 as well. Our export share above 80 % is due to the steady further developments of practical production-systems with the newest technology.

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