PP Honeycomb Board Line

Name: PP Honeycomb Board Line
Brand: JWELL
SKU: pp-honeycomb-board-line

Single Screw Extruder | Vacuum Thermoforming Drum | 200-500 kg/h | 1200-2500 mm | 2-20 mm | 200-800 GSM Core

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See the PP Honeycomb Board Line in Action

Factory Acceptance Test — Jwell Manufacturing Facility

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.

PP Honeycomb Board Line: Related JWELL Extrusion Lines

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.

Key Features

#	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

Proprietary Rotary Vacuum Thermoforming Drum — 97% Honeycomb Cell Fill Rate

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

Inline Thermal Fusion Bonding — No Adhesives, Full Panel Recyclability

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

Three Extruders, One Integrated Process — Core + Dual Face Sheet Synchronization

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

Single Pass Production — Extruder → Die → Vacuum Calibrator → Haul-Off → Annealing → Cooling → Corona → Coating → Cutter

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

Technical Specifications

Extruder Configuration

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

Panel Specifications

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

Thermoforming Drum

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

Bonding & Processing

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

Line Performance

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

Certifications & Support

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

[L] RELATED PRODUCTS 相关产品

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

[N] INQUIRY FORM 询价表单

#	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”

4.1 On-Page 元素

#	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 / ✅

4.2 E-E-A-T 信号强化

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

4.3 技术性能

检查项	目标值
LCP	< 2.5s
CLS	< 0.1
INP	< 200ms
Mobile-friendly	✅
图片格式	WebP (已满足)

5.1 已有图片资源

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) / ✅

5.2 已有视频资源

文件	用途 / 状态
视频/Jwell PP honeycomb board line FAT.mp4	[D] FAT 视频 / ✅

5.3 尚需补充的资源

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

本页链接到 (Outbound)

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”

从其他页面链接到本页 (Inbound)

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

Automotive Interior Panels — Trunk Floors, Parcel Shelves, Door Substrates

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.

Lightweight Logistics — Export Pallets, Returnable Containers, Protective Packaging

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.

Frequently Asked Questions

What is a PP honeycomb board extrusion line and how does it produce lightweight structural panels? -

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.

How does Jwell's rotary vacuum thermoforming drum compare to flat-bed vacuum forming for honeycomb production? +

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.

Does the PP honeycomb board line use adhesives for face sheet bonding? +

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.

What cell geometries and core densities can the line produce? +

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.

What is the production capacity and what panel sizes are available? +

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.