Single Screw Extruder | Vacuum Thermoforming Drum | 200-500 kg/h | 1200-2500 mm | 2-20 mm | 200-800 GSM Core
Complete production demonstration during FAT at Jwell’s manufacturing plant. Watch the full honeycomb board extrusion process from raw PP material through finished lightweight structural panel.
The PP Honeycomb Board Line is part of JWELL’s complete extrusion portfolio. Customers evaluating this PP Honeycomb Board Line also frequently request our PP Hollow Grid Sheet Line | Jwell Machinery and PP Thick Plate Extrusion Line | 3-30mm | 500-800kg/h | Jwell Machinery, which share the same proven screw, die and control platforms. For layout drawings, pricing and lead times, contact JWELL Machinery directly.
| # | Item | Key Point |
| 1 | 🌀 **97% Cell Fill Rate** | proprietary rotary vacuum thermoforming drum technology |
| 2 | ⚡ **Adhesive-Free Thermal Fusion Bonding** | 100% recyclable mono-material PP panel |
| 3 | 🎯 **Triple-Extruder Architecture** | independent core + dual face sheet extrusion |
| 4 | 🔄 **200-500 kg/h Output** | industry-leading honeycomb board production capacity |
| 5 | 🔧 **200-800 GSM Core Density** | unmatched strength-to-weight ratio in thermoplastic panels |
| 6 | ✅ **Interchangeable Cell Geometry** | 6/8/10 mm hexagon, circular cell options |
| 7 | ♻️ **Full Line Integration** | extrusion → vacuum forming → bonding → annealing → corona → coating → cutting |
| 8 | 🌍 **Zero Water Absorption** | sealed hexagonal cell structure, <0.1% by volume |
The heart of Jwell’s PP honeycomb board extrusion line is the proprietary rotary vacuum thermoforming drum — a precision-engineered cylinder that continuously forms the hexagonal honeycomb core structure from extruded PP melt web. Unlike reciprocating flat-bed vacuum forming systems that suffer from cyclic heating-cooling variation and cell quality inconsistency between press cycles, the rotary drum design provides continuous production with inherently higher output (30-50% more linear speed) and uniform cell geometry across every production minute.
The drum maintains surface temperature within ±1.5°C across its entire circumference through a multi-zone internal heating system, eliminating the temperature variation that causes cell wall thickness inconsistency. Precisely machined cavity geometry and vacuum distribution channels ensure uniform cell wall thickness of 0.15-0.30 mm throughout the honeycomb core. The drum achieves a cell fill rate exceeding 97% — meaning fewer than 3% of cells have wall defects or incomplete formation — producing honeycomb core with predictable and consistent mechanical properties.
Interchangeable cavity inserts enable manufacturers to configure cell size (6 mm, 8 mm, or 10 mm hexagon side length), cell wall angle, and cell orientation (vertical, diagonal, or mixed) to optimize for compressive strength, shear strength, or thermal insulation performance across different application requirements. The drum is available in Φ800 mm and Φ1,000 mm diameters to match different output configurations.
配图建议: 真空成型鼓近景照片，展示蜂窝结构成型过程
Jwell’s inline thermal-fusion bonding technology eliminates the need for adhesive films, hot-melt glues, or PUR reactive adhesives when joining face sheets to the honeycomb core. The system applies precisely controlled thermal energy at the interface between the extruded face sheet and the honeycomb core, creating a homogeneous PP-to-PP molecular bond that achieves peel strength above 15 N/25mm — exceeding adhesive-bonded alternatives — without introducing foreign material layers.
This adhesive-free approach delivers three fundamental advantages:
Cost Reduction: Eliminates adhesive raw material costs, typically US$0.15-0.25 per square meter, and removes the need for adhesive application equipment, curing time, and solvent handling infrastructure.
Superior Bond Performance: The molecular-level PP-to-PP bond provides higher peel strength than adhesive interlayers and eliminates the failure mode of adhesive delamination under thermal cycling, moisture exposure, and mechanical fatigue — common failure modes in adhesive-bonded honeycomb panels used in automotive and outdoor applications.
Full Recyclability: Because the entire panel — core and both face sheets — is a single material (PP), the finished product can be ground, pelletized, and re-extruded as homogeneous PP feedstock. This 100% recyclability supports European ELV (End-of-Life Vehicle) directive compliance for automotive components and circular economy certification for packaging and furniture applications. The absence of adhesive residues means the recycled material quality equals virgin PP for most re-extrusion applications.
配图建议: 热熔粘合区域近景或粘合界面截面图
The production of consistent honeycomb panels demands precise coordination between three independent extruders — one for the honeycomb core web and one each for the top and bottom face sheets. Even minor flow imbalances between core and face sheet extruders cause thickness variation, warpage, or bonding defects that render panels unacceptable for automotive and furniture applications.
Jwell’s master-slave PLC architecture (Siemens S7-1500) continuously monitors melt pressure at each extruder die head and adjusts screw RPM in closed-loop control with a scan time under 100 milliseconds. This real-time synchronization maintains melt output balance within ±0.5% across all three streams, ensuring that face sheet thickness at panel edges matches center thickness within ±0.03 mm — a critical quality parameter for edge-banding applications.
The triple-extruder configuration also enables functional material flexibility. The top face sheet, honeycomb core, and bottom face sheet can each use different PP compounds. For example: a textured FR-grade black face sheet on one side for durability, a smooth natural-grade face sheet on the reverse for gluing or laminating, and a standard PP core for cost optimization. Color changes are accomplished through masterbatch dosing at each extruder throat without cross-contamination between streams.
Main extruder specifications:
– Core Extruder: Φ90 mm / Φ120 mm screw, 30:1 L/D with PP barrier screw
– Face Sheet Extruders: Φ65 mm / Φ90 mm (2 units for top/bottom)
– Total Installed Power: 90-220 kW (combined for 3 extruders)
配图建议: 三台挤出机布局照片或产线俯视图
Jwell’s PP honeycomb board line integrates the complete production sequence into a single continuous process, eliminating the offline handling, storage, and secondary processing steps required by multi-stage manufacturing approaches:
1. Single Screw Extrusion: PP melt generation with barrier screw delivering homogeneous melt at controlled temperature for consistent cell formation
2. Sheet Die: Precision flexible-lip die producing uniform melt web width for the honeycomb core
3. Vacuum Calibrator/Thermoforming Drum: Continuous honeycomb cell formation with 97% fill rate on the rotary drum
4. Haul-Off: Precision speed-controlled pulling maintaining web tension stability through the forming and bonding sections
5. Annealing Section: Controlled-temperature tunnel that relieves internal stress from the thermoforming and bonding processes, ensuring panel flatness retention
6. Cooling Section: Graduated multi-roller cooling conveyor reducing panel temperature at controlled rate to prevent warpage
7. Corona Treatment: Inline surface activation for improved coating adhesion and printability (optional)
8. Coating Station: Inline application of functional coatings — UV protection, anti-static, decorative, or primer for downstream lamination
9. Panel Cutter: Precision cross-cut saw cutting panels to customer-specified dimensions
This full integration means the line converts PP resin pellets into finished, dimensionally accurate honeycomb panels in one continuous pass, typically at haul-off speeds of 0.5-8.0 m/min depending on panel thickness and configuration.
配图建议: 产线全貌图，标注各工段位置
| Parameter | Specification |
| Extruder Type | Single-screw (3 independent: 1 core + 2 face sheet) |
| Core Extruder Screw Diameter | Φ90 mm / Φ120 mm |
| Face Sheet Extruder Screw Diameter | Φ65 mm / Φ90 mm (2 units) |
| L/D Ratio | 30:1 with PP barrier screw |
| Screw Material | Nitrided steel, 950 HV surface hardness |
| Total Installed Power | 90-220 kW (combined for 3 extruders) |
| Heating Type | Ceramic band heaters, multi-zone PID controlled |
| Parameter | Specification |
| Applicable Material | PP homopolymer, PP copolymer, PP + glass fiber (up to 20%) |
| Panel Width | 1,200 mm, 1,600 mm, 2,000 mm, 2,500 mm |
| Panel Thickness | 2 – 20 mm |
| Core Density | 200 – 800 GSM |
| Core Density (volumetric) | 60 – 120 kg/m³ |
| Face Sheet Thickness | 0.3 – 2.0 mm per side |
| Core Structure | Hexagonal honeycomb, circular honeycomb |
| Parameter | Specification |
| Drum Type | Rotary vacuum thermoforming, continuous operation |
| Drum Diameter | Φ800 mm / Φ1,000 mm |
| Cell Fill Rate | ≥97% |
| Cell Size Options | 6 mm, 8 mm, 10 mm (hexagon side length) |
| Cell Wall Thickness | 0.15 – 0.30 mm |
| Drum Temperature Control | Multi-zone, ±1.5°C uniformity |
| Cavity Inserts | Interchangeable, 4-6 hour changeover |
| Parameter | Specification |
| Bonding System | Inline hot-melt thermal fusion (no adhesive) |
| Peel Strength | >15 N/25mm |
| Annealing Section | 4-6 m tunnel, 4-zone temperature control |
| Annealing Temperature | 100-130°C (zone programmable) |
| Cooling Section | Multi-roller graduated cooling conveyor |
| Corona Treatment | Inline, 42-48 mN/m surface energy |
| Coating Station | Inline roller/spray, water-based/UV/solvent |
| Parameter | Specification |
| Production Capacity | 200 – 500 kg/h |
| Haul-Off Speed | 0.5 – 8.0 m/min |
| Control System | Siemens S7-1500 PLC with cell-formation monitoring |
| HMI | 15-inch touchscreen, recipe storage |
| Process Parameters Logged | 50+ at 10-second intervals |
| Parameter | Specification |
| Certifications | CE, ISO 9001 |
| Available as | Complete line turnkey solution |
| After-Sales | Global engineer certification system, 48-hour spare parts dispatch |
| Warranty | 1 year from commissioning or 18 months from dispatch |
| 卡片 | 产品名称 / 链接 / 关系 |
| 1 | PP Hollow Sheet Extrusion Line / /sheet-extrusion/pp-hollow-sheet-extrusion-line/ / 同类PP基材料，中空结构板材 |
| 2 | PP Solid Plate Extrusion Line / /sheet-extrusion/pp-solid-plate-extrusion-line/ / 同类PP基材料，实心厚板 |
| 3 | PP Hollow Grid Sheet Line / /sheet-extrusion/pp-hollow-grid-sheet-line/ / 同类PP基材料，网格中空结构 |
| # | 字段 / 类型 / 必填 / 说明 |
| 1 | Name / text / ✅ / placeholder: “Your full name” |
| 2 | Email / email / ✅ / placeholder: “your@company.com” |
| 3 | Country / select / ✅ / 200+国家 |
| 4 | Phone / tel / — / 含国际区号 |
| 5 | Company / text / — / placeholder: “Your company name” |
| 6 | Application / select / ✅ / Automotive Interior / Packaging & Logistics / Construction Formwork / Signage & Display / Furniture / Multiple / Other |
| 7 | Target Material / select / ✅ / PP Homopolymer / PP Copolymer / PP + Glass Fiber / Not sure |
| 8 | Required Output (kg/h) / select / ✅ / <200 / 200-350 / 350-500 / >500 / Not sure |
| 9 | Panel Width (mm) / select / — / 1200 / 1600 / 2000 / 2500 / Not sure |
| 10 | Panel Thickness (mm) / select / — / 2-5 / 5-10 / 10-15 / 15-20 / Not sure |
| 11 | Cell Configuration / select / — / Hexagonal 6mm / Hexagonal 8mm / Hexagonal 10mm / Circular / Not sure |
| 12 | Surface Treatment / select / — / Corona + Coating / Corona Only / No Treatment / Not sure |
| 13 | Project Timeline / select / — / Immediate / 1-3 months / 3-6 months / 6-12 months / Information only |
| 14 | Message / textarea / — / placeholder: “Tell us about your production requirements, target application, and any special needs…” |
| — | CAPTCHA / — / ✅ / reCAPTCHA v3 |
| — | Submit / submit / — / “Request Quote & Configuration” |
| # | 检查项 / 状态 |
| 1 | 唯一 H1，含完整产品名 + 核心关键词 / ✅ |
| 2 | H2 技术关键词覆盖: vacuum thermoforming, thermal fusion, triple-extruder, honeycomb core, corona treatment / ✅ |
| 3 | 规格表为 HTML <table> 文本 / ✅ |
| 4 | 所有图片有描述性 alt 属性 / ✅ |
| 5 | 面包屑用 Schema BreadcrumbList / ✅ |
| 6 | FAQ 用 Schema FAQPage (6个Q&A) / ✅ |
| 7 | 产品信息用 Schema Product + 详细 Organization / ✅ |
| 8 | 视频用 Schema VideoObject / ✅ |
| 9 | Canonical 自引用 / ✅ |
| 10 | Title tag 50-60 chars / ✅ |
| 11 | Meta description 含关键词 + 规格数据 / ✅ |
| 12 | Open Graph 完整 / ✅ |
| 信号 | 体现方式 |
| Experience | 29年制造经验、8个生产基地、25,000+台交付机器、15个国家运营产线 |
| Expertise | 自有真空成型鼓技术、热熔粘合无胶工艺、97%蜂巢填充率、1000+专利 |
| Authoritativeness | 中国塑机协会副会长单位、收购德国考特斯(2024)、CE+ISO 9001 |
| Trustworthiness | 全球工程师认证体系、48小时备件发货、8大生产基地、US$700M+营收 |
| 检查项 | 目标值 |
| LCP | < 2.5s |
| CLS | < 0.1 |
| INP | < 200ms |
| Mobile-friendly | ✅ |
| 图片格式 | WebP (已满足) |
| 文件夹 | 文件 / 用途 / 状态 |
| 主图/ | pp-honeycomb-board-extrusion-line-hero-01.webp / [C] Hero 画廊 — 主图 1 / ✅ |
| 主图/ | pp-honeycomb-board-extrusion-line-hero.webp / [C] Hero 画廊 — 主机特写 / ✅ |
| 详情图/ | pp-honeycomb-board-extrusion-line-automotive-lightweight-interior-components.webp / [H1] 汽车应用 / ✅ |
| 详情图/ | pp-honeycomb-board-extrusion-line-commercial-furniture-retail-fixtures.webp / [H5] 家具应用 / ✅ |
| 详情图/ | pp-honeycomb-board-extrusion-line-marine-interior-joinery.webp / 船舶应用(备用) / ✅ |
| 详情图/ | pp-honeycomb-board-extrusion-line-aerospace-ground-support-transport-cases.webp / 航空应用(备用) / ✅ |
| 文件 | 用途 / 状态 |
| 视频/Jwell PP honeycomb board line FAT.mp4 | [D] FAT 视频 / ✅ |
| 用途 | 建议 / 优先级 |
| H2 包装托盘配图 | 蜂窝板包装托盘应用照片 / 高 |
| H3 建筑模板配图 | 蜂窝板建筑模板应用照片 / 高 |
| H4 广告展示板配图 | 蜂窝板广告展示应用照片 / 高 |
| F1 真空成型鼓配图 | 成型鼓近景特写 / 高 |
| F2 粘合界面配图 | 热熔粘合区域截面图 / 中 |
| F3 三挤出机布局 | 挤出机布局或产线俯视图 / 中 |
| F5 蜂窝结构对比 | 不同蜂巢几何结构对比图 / 中 |
| F7 退火隧道配图 | 退火隧道近景 / 低 |
| F8 电晕涂布配图 | 电晕处理或涂布站近景 / 低 |
| D1 视频封面图 | FAT 视频 poster 图 / 高 |
| 目标页面 | 位置 / 锚文本 |
| PP Hollow Sheet Line | [L] Related Products / “PP Hollow Sheet Extrusion Line” |
| PP Solid Plate Line | [L] Related Products / “PP Solid Plate Extrusion Line” |
| PP Hollow Grid Sheet Line | [L] Related Products / “PP Hollow Grid Sheet Extrusion Line” |
| 来源页面 | 链接上下文 |
| Sheet Extrusion Pillar Page | 片材挤出分类页 |
| Automotive Lightweight Materials Guide | 汽车轻量化解决方案 |
| Packaging & Logistics Equipment Guide | 包装物流设备指南 |
| Construction Formwork Solutions | 建筑模板解决方案 |
European and Asian OEMs increasingly specify PP honeycomb panels for trunk load floors where the 60-70% weight reduction versus wood-fiber alternatives directly supports fleet CO₂ emission targets and electric vehicle range extension. The material provides sufficient stiffness for full-size spare tire coverage without reinforcements, survives 1,000+ trunk loading cycles without permanent deformation, and is fully recyclable within the vehicle’s PP waste stream — a critical advantage for ELV directive compliance.
Additional automotive applications include parcel shelves (where the material’s light weight simplifies hinge and support design), door panel substrates (where honeycomb replaces heavier ABS or wood-fiber panels), and headliners (where the material’s thermal insulation properties contribute to cabin comfort). PP honeycomb’s zero water absorption eliminates the swelling and mold issues that affect natural-fiber automotive panels in humid climates.
配图: (建议补充包装托盘应用图片)
Export pallets and returnable logistics containers manufactured from PP honeycomb board weigh 60-70% less than equivalent wooden pallets while meeting ISPM 15 exemption requirements for international shipping — PP requires no fumigation or heat treatment. The material’s complete moisture resistance eliminates the warping and degradation that affect wooden pallets in humid shipping containers, and its impact absorption properties protect goods during transit.
Reusable container systems for automotive parts delivery, electronics logistics, and pharmaceutical cold-chain transport benefit from PP honeycomb’s combination of light weight (reducing freight cost), durability (surviving hundreds of handling cycles), cleanability (washable surface for hygiene-critical applications), and full recyclability at end of life.
A PP honeycomb board extrusion line produces polypropylene panels with a hexagonal honeycomb core structure sandwiched between solid face sheets — all in a single continuous process. The line integrates a single-screw extruder feeding a sheet die, a rotary vacuum thermoforming drum that forms the honeycomb cell geometry from the extruded melt web, and an inline thermal fusion bonding system that fuses top and bottom face sheets to the core without adhesives. The result is a lightweight structural panel (200-800 GSM core density) with exceptional strength-to-weight ratio, 100% recyclability as mono-material PP, and complete resistance to water and most chemicals. Jwell lines deliver 200-500 kg/h output with panel widths from 1,200 to 2,500 mm at 2-20 mm thickness.
The rotary drum design provides continuous production with inherently higher output — 30-50% more linear speed — compared to reciprocating flat-bed systems. More importantly, the drum’s consistent circumferential temperature eliminates the cyclic heating-cooling variation of flat-bed systems that causes cell quality variation between the start and end of each press cycle. Jwell’s drum maintains surface temperature within ±1.5°C across its full circumference, producing uniform cell geometry and wall thickness throughout every production minute. The interchangeable cavity insert system also enables rapid changeover between cell sizes (6/8/10 mm) and geometries (hexagonal or circular) without replacing the entire drum.
No. Jwell uses inline thermal-fusion bonding technology that fuses the face sheets to the honeycomb core using precisely controlled thermal energy at the interface surface. This creates a homogeneous PP-to-PP molecular bond — achieving peel strengths above 15 N/25mm — without introducing adhesive films, hot-melt glues, or PUR reactive adhesives. The adhesive-free construction eliminates adhesive costs (approximately US$0.15-0.25/m²), achieves higher and more consistent bond strength than adhesive alternatives, and enables 100% panel recyclability as mono-material PP. For automotive customers, this recyclability is critical for ELV directive compliance; for packaging and furniture customers, it supports circular economy certification.
The Jwell line supports hexagonal honeycomb cells at 6 mm, 8 mm, and 10 mm side lengths, plus circular cell geometry, through interchangeable cavity inserts on the vacuum thermoforming drum. Core density is adjustable from 200 GSM (ultra-lightweight for displays and packaging) to 800 GSM (structural grade for load-bearing applications). Face sheet thickness is independently controlled from 0.3 to 2.0 mm per side. This programmability means one line can produce ultra-light panels for trade show displays in the morning shift, medium-density panels for furniture in the afternoon, and structural-grade panels for automotive applications in the night shift — maximizing capital equipment utilization.
The PP honeycomb board extrusion line delivers 200-500 kg/h output, with panel width options of 1,200 mm, 1,600 mm, 2,000 mm, and 2,500 mm, and panel thickness range of 2-20 mm. The three-extruder configuration (Φ90/120 mm core extruder + two Φ65/90 mm face sheet extruders) provides a total installed power of 90-220 kW. Haul-off speed ranges from 0.5 to 8.0 m/min depending on panel thickness and line configuration. The Siemens S7-1500 PLC stores calibrated process recipes for each panel specification, enabling rapid product changeover with minimum startup scrap.
Extruder Type: Conical twin-screw, vented; Screw Material: 38CrMoAlA, nitrided, bimetallic optional; Screw Structure: Conical twin, designed for PVC + wood flour + CaCO₃ + foaming agent; L/D Ratio: Optimized for controlled foaming zone
Screw Diameter: Φ 80 mm / Φ 92 mm / Φ 110 mm / Φ 180 mm; Output (24h, SPC): 6-8 T / 12-18 T / 25-32 T / 70-100 T; Line Speed at 4 mm: 0.4-0.6 m/min / 0.8-1.3 m/min / 1.8-2.4 m/min / 5-9 m/min; Screw Material: 38CrMoAlA, nitrided, bimetallic optional / ← Same / ← Same / ← Same
Applicable Material: EVA copolymer (VA content 14-28%), EVA + LDPE blends, EVA + carbon black; Sheet Width: 2,000 – 4,000 mm; Sheet Thickness: 1.0 – 3.0 mm; Production Capacity: 300 – 600 kg/h
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Jwell has manufactured PET sheet extrusion equipment since 2005, accumulating field data from over 400 installed PET lines worldwide. Each new machine generation incorporates refinements validated across hundreds of real production environments — not just lab prototypes.
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Our Changzhou facility operates a full production-scale PET line for customer trials. Bring your raw materials and target specifications — we run your recipe before you commit. The line delivered to your factory is a proven configuration, eliminating startup risk.
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Factory-trained Jwell engineers based in Brazil, Spain, Mexico, and Shanghai travel to customer sites for installation and operator training. Remote diagnostic support via WeChat/WhatsApp responds within 2 hours. Critical spares ship from Shanghai within 48 hours.
Jwell Machinery Co., Ltd sets up in 1997 , we are large manufacturer of plastic extrusion machinery in China, our headoffice was located in Shanghai.
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