Lines version upgrade list

To mark the 15th anniversary of our company in the FRP industry and the 5th anniversary since the start of production of our second-generation thin-diameter CG-4 lines, we have consolidated into a single document and decided to publish all improvements we have implemented for this line since its launch.

Modularity and mobility

•  An upgraded design now allows three lines to be transported in a single container instead of one, which significantly reduces delivery costs.

• The installation and commissioning scheme of the line has been improved.

• The electrical infrastructure has been modernized.

• These improvements enable the line to be used as a “mobile production unit”. You can now disconnect the line, move it to another location, and reconnect it again. The disconnection and reconnection procedure takes 15 minutes. This upgrade allows you to place the line at any site, including next to a construction site, and produce the product directly on location.

Impregnation baths and squeezing system

• A new combined unit “Bath + Rib Winder” (two-in-one) reduces compound losses during production.

• The optimized roving “angle of attack” and squeezing system have been continuously upgraded over three years until maximum efficiency was achieved. This allows using more than 82% glass in the composition, reduces the risk of damage before the polymerization zone and decreases the percentage of hidden defects.

• Drum impregnation method.

Roving racks.

• Ceramic dies.

• Weight sensors.

• Gentle payoff and monitoring of raw material consumption.

Polymerization

• The polymerization ovens have been improved. The oven is now modular, with each module 1.5 meters long. This improves final product quality. By purchasing additional modules, you can extend the oven to any required length. This enables performance optimization of the line for different diameters.

• The oven walls have been thickened. New modern materials are used, which make the oven safer; the shell temperature does not exceed 50 degrees Celsius. This eliminates burn risks for operators, increases oven efficiency and reduces power consumption.

Cooling system

• The cooling system has been upgraded. New guides for targeted water distribution help avoid thermal shock. This improvement has a positive effect on the alkali resistance of the product by reducing the formation of microcracks.

• The cooling system allows the line to be equipped with an additional integrated chiller for operation in regions with extremely hot climates.

Typical line customization

• Additional polymerization ovens (for higher production speeds) or as part of the Long Edition configuration.

• Additional air cooling (for higher speeds to avoid thermal shock) or as part of the Long Edition configuration.

• Spray nozzles for the cooling system (for higher speeds to avoid thermal shock) or as part of the Long Edition configuration.

• Rebar shaft drying after the cooling section (for regions with high humidity) or as part of the Long Edition configuration.

• Additional winder or as part of the Long Edition configuration.

Marking and measurement systems

• Linear meter marking system.

• Counter of produced GFRP rebar: per hour, per shift, per day, per week, per month.

• Actual bar diameter measuring device.

• Upgraded pneumatic squeezing system improves operator comfort and allows the operator to react instantly and perform the necessary adjustments for more precise process control.

Pulling unit

• It almost goes without saying that all of our second-generation lines are equipped only with two-caterpillar pulling units; rubber belts and polyurethane rolls remain in the first generation. But even this did not stop us from improving the pulling unit three times over the last five years.

• Optimized ratio of contact pressure and number of shoes.

• Increased motor power enables continuous production of 4–12 mm in four strands, 14–18 mm in two strands and, in limited volumes and small batches, subject to coordination with the equipment manufacturer, up to 34 mm diameter in a single strand (a non-recommended but feasible application of the line. For larger diameters we recommend purchasing a CG1 line for 20–42 mm).

• Increased structural safety margin of the module.

Reduced overheating risks.

Automatic pneumatic clamping extends the service life of polyurethane shoes, increases the replacement interval for spare parts by a factor of three and prevents bar slippage.

Cutting unit

• Equipped with a more powerful motor.

• Uses a cutting disc of larger diameter.

• The module is equipped with a new protection circuit to prevent jamming.

• The vertical and horizontal travel of the cutting head has been optimized.

• Cutting operation speed has been increased.

Winder

• The coil winding system has been improved.

• A new winding operation concept has been introduced to simplify the work of the winder operator.

• A pneumatic clamp has been implemented, allowing the winding cycle to be completed automatically without distracting the operator from other tasks. This enables one person to efficiently operate the entire line.

Safety

Overall line safety has been increased. In this modification you will see that all moving parts are protected and enclosed by additional guards, and opening these guards stops the line.

Control panel

A secondary, remote, portable control panel duplicates the main line control for the operator on the shop floor.

Scope of supply

The standard scope of supply includes a ventilation system drawing. Installation of an exhaust system according to this drawing and with adherence to the specified parameters of the system and motor helps reduce fire risks, prevent electrical failures, improve operator health protection and increase comfort.

A basic repair kit is included in the price.

Country-specific modifications are possible in terms of electrical specifications, operating temperature ranges, line footprint, productivity, number of operators and thermal insulation of individual units.
Engineering customization beyond the standard serial configurations is also available.