Sure Plastic Machinery uses high-quality embossing rollers to upgrade the quality of wood plastic flooring.
As the core component in the production process of wood plastic flooring, the performance of the embossing roller directly affects more than 80% of the product's appearance and physical indicators. Sure Plastic Machinery follows strict standards in the selection of embossing rollers, and has made all-round considerations from material performance to process adaptability. In terms of material, 42CrMo high-strength alloy steel is selected as the roller base material, with a 25μm thick chrome plating layer, and the surface hardness reaches HV1200. It can withstand 15MPa high pressure and 220℃ high temperature environment. Compared with ordinary carbon steel rollers, the service life is extended by more than 3 times. At the same time, the vacuum quenching process controls the thermal conductivity uniformity error of the roller within ±1.5℃, effectively avoiding texture distortion caused by uneven temperature, and reducing the product defective rate to less than 2%.
In terms of texture design and processing accuracy, Sure Plastic Machinery has demonstrated strong technical strength. The laser engraving process can achieve a 50μm-level texture accuracy. Through reverse engineering technology, the duct and annual ring structure of natural wood can be reproduced 1:1, with a simulation degree of up to 98%. The cylindrical error of the roller body is controlled within 0.008mm, and the surface roughness Ra value reaches 0.6μm, ensuring that the pressure is evenly distributed during the embossing process. When producing imitation walnut texture floors, the 0.3mm wide duct structure of the wood and the 0.1mm deep annual ring groove can be clearly presented. The produced floor has clear texture and sharp edges, without "burrs" or "collapse".
High-quality embossing rollers have a significant effect on improving the physical properties of wood-plastic flooring. Sure Plastic Machinery optimizes the embossing process to form a 0.8mm deep diamond anti-slip texture on the floor surface. After testing, the friction coefficient reaches 0.68 (DIN standard), which is more than 40% higher than ordinary floors. At the same time, the concave and convex texture improves the acoustic performance of the floor, increasing the absorption of footsteps by 25%, creating a quieter living environment. In addition, the high temperature and high pressure treatment during the embossing process increases the surface density of the wood-plastic material from 1.2g/cm³ to 1.4g/cm³. Combined with the UV coating process, the wear-resistant revolutions reach 15,000 revolutions (Taber test), which is 35% higher than ordinary products, effectively extending the product life.
In the process of customizing high-quality embossing rollers, Sure Plastic Machinery has established a complete technical system. In the early stage of demand analysis, according to the target market positioning, a 0.2mm shallow wood grain embossing roller was customized for the home improvement market, and the surface gloss was controlled at 12±2GU to meet consumers' demand for delicate touch and soft vision; for the commercial workwear market, a 0.6mm deep relief anti-slip embossing roller was customized, and the wear resistance level reached the T level of the EN 660-2 standard. In terms of material selection, through joint development with suppliers, nickel-phosphorus alloy plating is used, and the salt spray test time is more than 1000 hours without corrosion, far exceeding the industry standard of 500 hours.
In the production process, Sure Plastic Machinery requires suppliers to pass the three-coordinate measuring instrument inspection for each embossing roller, issue 12 geometric accuracy inspection reports such as cylindricity and coaxiality, and conduct dynamic balancing grade G2.5 certification, and the residual imbalance is controlled within 1.8g・mm/kg. In the trial production stage, the texture consistency test was carried out by pressing 1000 meters of substrate, and the gloss error was controlled within ±3GU, the dimensional deviation width ≤±0.2mm, and the thickness ≤±0.08mm, ensuring the perfect fit of the embossing roller and the production line.
In terms of production efficiency and cost control, Sure Plastic Machinery's high-quality embossing rollers also perform well. By selecting a high-precision temperature-controlled embossing roller equipped with a constant pressure system driven by a servo motor, seamless switching of production line speeds from 5 to 20m/min can be achieved, with a texture consistency error of ≤±2% at different line speeds, reducing the defective rate of finished products from 8% to 3%, and increasing production efficiency by 30%. At the same time, the high durability of the embossing roller reduces equipment maintenance costs. Its chrome plating layer can withstand more than 5 million pressing cycles. After producing 800,000 square meters, the texture depth loss is still ≤3%, reducing downtime and economic costs caused by frequent roller replacement.
The relevant person in charge of Sure Plastic Machinery said: "High-quality embossing rollers are a key link in improving the competitiveness of our products. In the future, we will continue to keep up with the development trend of industry technology, introduce more advanced multi-roller combination processes, intelligent temperature control and other technologies, and promote the development of wood-plastic flooring towards high-end and personalized directions, bringing more high-quality green building materials products to consumers."
With the precise selection and innovative application of high-quality embossing rollers, Sure Plastic Machinery has not only achieved a comprehensive improvement in the quality and grade of wood-plastic flooring products, but also stood out in the fiercely competitive market, providing a successful example for the high-quality development of the industry.
