Mix Process
PVC Resin is blended dry with Plasticiser. The mixture is subjected to a specific temperature to induce the plasticizing effect. These include blending in UV stabilizers and other additives to ensure uniform distribution. After kneading, the mass is transferred to the extruder for further processing.
Extrusion
Extrusion is the most critical process in the manufacturing of PVC curtains. The mixed PVC composition is fed into the extruder, which contains a rotating screw inside a heated barrel. The material melts upon attaining high pressure and temperature with the movement in the screw.
Rib Formation and Molding
The molten PVC is placed in the mold, and the ribbed texture of the PVC curtain is achieved using a special mold, which molds the curtain into angular ridges with a triangular mold. This important step ensures that the ribs are equally put across the surface for the expected durability.
Mold Design: The mold section is triangular-shaped, compressing the PVC sheet under extrusion to form raised ribs on one side of the curtain.
Thickness Control: This process measures the curtain's thickness to ensure consistency throughout the roll. Rib heights range from 1 mm to 3 mm, depending on the application.
Cooling and Curing
After extrusion and rib formation, the curtain is solidified at a cooling station. Rapid cooling ensures the curtain retains its shape without distortion.
Cooling Conveyor: The extruded PVC passes through a cooling chamber where cold air or water jets reduce its temperature.
Curing: The PVC hardens into its final form, ensuring the triangular ribs are fully embedded and maintain their shape.
Cutting and Shaping
The ribbed PVC is then cut into sheets or lengths as required for its specific application.
Precision Cutting: An automated cutting machine trims the curtain roll to the desired dimensions.
Edge Finishing: The edges are smoothed to remove any sharp or rough areas that might affect performance during installation.
Rolling Up the Curtains
After cutting, the curtains are rolled onto reels for storage and shipping.
Rolling Up Process: An automatic rolling machine winds the cut lengths into rolls, ensuring consistent tension. Excessive tension can deform the ribs, while insufficient tension may cause the rolls to loosen.
Quality Control: Each roll is checked for rib height, transparency, and thickness. Any defects, such as uneven ribs or bubbles, are corrected before packaging.
