BLOCK MOULDING SYSTEM
Blockmould TNG
EPS Blockmoulds transform pre-expanded beads into premium EPS blocks and boards. The mold shapes and holds the pre-foam while steam is applied to promote final expansion Through precise steam application, the beads fuse together, creating a durable, homogeneous final product.
Maximize your EPS manufacturing profitability with the VIRO Type TNG Blockmould. Engineered for efficiency, this high-performance system delivers an exceptionally narrow density distribution to save on raw materials. Testing shows that over 90% of block sheets maintain a density variance of +/- 1.5% or better, with a maximum distribution of just +/- 2.5% from average required density.
FEATURES
- Fully adjustable block size
- Hydraulic compression for elastification
- Unique screen assembly system
- Exhaust air cleaning cyclones
- PID and temperature-controlled steam flow
- Steam consumption measurement
- Block weight monitoring and control
- Recipe management
- SIEMENS SCADA PLC S7
- HMI touchscreen with graphical user interface
HIGHLIGHTS
- Excellent, narrow density gradient
- Perfect fusion with low residual moisture content
- High-capacity output
- Energy-efficient and eco-friendly operation
- Machine body rated according to P.E.D. 2014/68/EU
ADVANTAGES
- Fewer cleaning cycles and significantly reduced downtime for screen cleaning
- No cooling water consumption or evaporation
- Eliminates the need for hot and cold water tanks
- Eliminates costs for chemical additives
- Minimizes water oxygenation compared to traditional open chillers
- No risk of water freezing in the cooling tower
- No steam released into the environment
- No roof emissions or noise
- Preheats boiler feed water (via water/water heat exchanger)
- Provides plant heating during winter (via water/air heat exchanger)
- Heats and ventilates the silo room (via water/air heat exchanger)
Advanced Filling System
The filling process is completed rapidly to prevent unnecessary cooling of the steam screens and the top mould area. A heating device keeps the fill gun area constantly hot, effectively eliminating excess condensation and wet spots. VIRO’s TNG blockmould system allows to clean the filling air, drawn during each cycle, ensuring no contaminants, fines, fluffs, or beads are released into the environment. Designed without a chimney, the TNG system operates with zero roof emissions-meaning no overhead sound, no airborne contaminants, and no steam losses.
Special Screen System
Our unique screen system utilizes a screwless cartridge design for fixing steam plates. With only four screws at the top needed to open the entire system, lightweight screen cartridges simply slide and click into the frame. Unlike traditional wedge wire screens that clog easily and are time-consuming to remove, our screens require virtually no cleaning. Dust and debris are safely directed behind the screens into an exceptionally deep steam chest. This allows the system to produce up to 15.000 blocks (white EPS) without any reduction in quality or performance before a cleaning cycle is required.
Adjustable Rear Wall for Density Control
The adjustable rear wall allows operators to precisely optimize both block size and density. This mechanism also enables moulding of blocks using 100% scrap material.
The density correction process includes:
- Determining bulk density via weighing cells at the filling silo (or at the VIRO Compactmix Station)
- Calculating the differential weight
- Managing volume expansion by adjusting the rear wall
- Refilling and resetting the rear wall to achieve the perfect target density
Closed-loop vacuum system for energy recuperation
This innovative closed-loop water cooling system is designed to absorb steam energy used during each moulding cycle. The system is completely self-sufficient, using only steam condensate to backflush filters and feed the vacuum pumps, no additional water supply is required after the initial filling. Thermal energy that is not used for the moulding and fusion process is recycled and can be used for:
- Heating buildings (infrared heating elements below the roof)
- Preheating boiler feed water
- Heating silos for faster curing of EPS beads
The closed-loop water circuit maintains system stability and enables the use of significantly higher vacuum pressures. While standard blockmould systems operate at 0,25 to 0,4 bar negative pressure (approx. 750–600 mbar absolute), our DRY VACUUM starts at a powerful 0,75 negative pressure (or 250 mbar absolute). This higher vacuum allows steam to cross into the bead bulk for longer periods without “burning” the material. The result is perfectly homogeneous energy penetration, enabling higher foam pressures at much lower cycle times.
