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Cellulose Insulation Technology

Fibretec Production Lines

Succeed with Green technology


- Convert newsprint into greenbacks!
ENG

Fibretec 1000

-basic economical, economical


& advanced system-

Example layout

Fibretec 1000 is an economical system for starting


cellulose insulation manufacturing business. It consists
of a basic set-up of high quality equipment optimized for
1000 kg/hour capacity. Manually operated paper feeding
and insulation packaging systems are easy to use and
control.
In this case, the recycled paper comes to the factory
in loose form. Pre-crushing is performed by a sturdy
Hammermill. Final refining is performed by the
powerful 30 Fiberizer, which refines the paper into
very fluffy insulation with the best coverage and lowest
settled density. At the end of the line, the insulation is
packed in paper sacks using the screw driven
Packaging Unit. Dust collection takes place effectively
by separating process air from the material flow by the
Cyclone Separators and by leading the air through the
self-cleaning Dust Filter Unit.
The Fibretec 1000 can be offered with several
automation levels. An automated paper feeding system
makes it possible to use compressed paper bales as raw
material. Two types of packaging systems are availabe.
The insulation can be packed into pre-fabricated paper
sacks or pre-fabricated plastic sacks.

3.

Pre-handling Table

12. Fiberizer Model 30

2.

Feeding Conveyor

13. Blower 3

3.

Hammermill

14. Cyclone Separator 2

4.

Trash Separator

5.

Blower 1

6.

Cyclone Separator 1

7.

Paper Surge Bin

8.

Feeding Device for


Chemical Additive 1

9.

15. Fiber Surge Bin


16. Packaging Machines

Feeding Device for


Chemical Additive 2

10. Chemical Blower

14.

7.

8.

9.

18. Lower Pressing Belt


19. Weighing Conveyor
20. Dust Filter Unit
21. Piping
22. Electric Control

System

Pulverizer(Option)

25. Spark Detection

&Extinguishing
System (Option)

(23. Spare Parts)

6.

17. Upper Pressing Belt

24. Chemical

11. Blower 2

A Chemical Pulverizer for improved fire retardant


properties of the chemical additives, as well as a Spark
Detection &Extinguishing System for improved safety of
the plant are also available as optional items.
1.

1.

24.

Fibretec 1000
-basic economical system-

14.
22.

20.

17

15.

19.

18.

Technical Data

16.

Effective capacity:
1000 kg/h x 16 h/day ~ 12800 kg / day

21.

(with 80 % work time efficiency)

25.
6.

13.

12.

Required space:
~ 400 m2 + ~ 300 m2
for storing the raw material and final product.

24.
5.

9.
11.

4.

7.

Power supply:
Voltage: 400/230 V, 50 Hz
Connected power ~ 260 kW (without optional items)

10.
8

3.

Free height of the hall:


min. 8000 mm

Compressed air supply:


Pressure Min 0,6 MPa - Max 0,7 MPa
Quantity ~ 600 l/min

2.

Water supply (only with optional item 25):


Pressure Min 0,2 MPa Max 0,6 MPa

1.

Operators:
4-5 persons per shift
Auxiliary equipment:
1 fork lift
1- 2 hand pallet trucks

1000-1200 kg/hour
70-80 bags/hour

Paper sack information


12.

16.

17. 18.

20.

Size of filled sack:


1000 x 500 x 250 mm (H x W x T)
Weight of filled sack:
13 - 15 kg (adjustable)

Fibretec 1500

-advanced & automated sytem-

Example layout

Fibretec 1500 includes the complete set of equipment


for manufacturing cellulose insulation up to 1800 kg per
hour. The advanced version is equipped with an
automated paper feeding system for paper bales as raw
material. The paper feeding to the process takes place
automatically. Also the use of recycled paper collected
from the households or the use of overnight unread
newsprint from printhouses is possible. The automated
version is equiped an automated packing system.
In a first stage the paper is shredded by an automated
Shredder. In a second stage refining is performed by the
powerful 42 Fiberizer, which refines the paper into very
fluffy insulation with the best coverage and lowest
settled density.
Dosing of the chemical additives takes place by accurate
volumetric dosing units. As an option the chemical
dosing system can be equipped with weighing sensors
and hoists for handling 1000 kg chemical sacks.

1.

Feeding Conveyor

12. Blower 3

2.

Paper Shredder

13. Cyclone Separator 2

3.

Blower 1

14. Fiber Surge Bin

4.

Cyclone Separator 1

15. Hydraulic Press

5.

Paper Surge Bin

6.

Dosing Device for


Chemical Additive 1

7.

Dosing Device for


Chemical Additive 2

8. Chemical Blower
9. Trash Separator

Packaging of the insulation can be performed by manual


packaging system with use of pre-fabricated paper
sacks or an automated packaging system with use of
plastic foil in a plastic bag form, fill and seal unit.

10. Blower 2
11. Fiberizer Model 42

1.

17. Weighing Conveyor


18. Belt Conveyor
19. Dust Filter Unit
20. Piping
22. Electric Control

System

23. Chemical Pulverizer

(Option)

24. Spark Detection

Dust collection takes place effectively by separating


the process air from the material flow by the Cyclone
Separators and by leading the air through the selfcleaning Dust Filter Unit.
A Chemical Pulverizer for improved
fire retardant properties of the
chemical additives, as well as the
Spark Detection &Extinguishing
System for improved safety of the
plant are also available as optional
items.

16. Flat Foil Seal Device

& Extinguishing
System (Option)

(21. Spare Parts)


2.

4.

13.

5.

6.

7.

23.

Fibretec 1500

13.

-automated system14.

19.

15.
21.

Technical Data
16.

20.

10.
24.

4.

Effective capacity:
1500 kg/h x 16 h/day~ 19200 kg / day

11.

18.

9.

Power supply:
Voltage: 400/230 V, 50 Hz
Connected power ~ 400 kW (without optional items)

8.
7.
2.

Required space:
~ 400 m2 + ~ 400 m2
for storing the raw material and final product.
Free height of the hall:
min. 9000 mm

23.

5.

1.

(with 80 % work time efficiency)

17.

12.

Compressed air supply:


Pressure Min 0,6 MPa - Max 0,7 MPa
Quantity ~ 600 l/min

6.

Water supply (only with optional item 24):


Pressure Min 0,2 MPa Max 0,6 MPa
3.

Operators:
2- 3 persons per shift
Other equipment:
1 fork lift
1- 2 hand pallet trucks

1500-1800 kg/hour
100-120 bags/hour

Packaging
11.

15.

16.

19.

21.

Plastic foil:
width of foil roll 1450-1500 mm
foil thickness
70 110 m
Size of finished bag:
length
780-800 mm (adjustable)
width
380-400 mm
thickness
325-350 mm
weight
13 - 15 kg (adjustable)
accuracy
+/- 0,5 kg

Fibretec 2000

-automated advanced system-

Example layout

Fibretec 2000 represents the highest level of technology


in cellulose insulation manufacturing industry. The
production line is optimized for a capacity of at least
2000 kg per hour. Only one key operator can keep the
production running while anther operator takes care of
the product storage.
The insulation is processed from the paper through our
effective 2-stage process. Braking of the complete paper
bales and the shreeding is performed by the un-manned
Shredder. In the second stage refining is performed by
the powerful 42 Fiberizer, which refines the paper into
very fluffy insulation with the best coverage and lowest
settled density.
The chemical additives are precisely dosed and
continuously weighed before they are mixed together,
to ensure the exact mix ratio and to control the
consumption of the costly chemical additives. With the
use of hoists it is easy for the operator to handle heavy
1000kg chemical bags.

1.

Bale Conveyor

13. Cyclone Separator 2

2.

Shredder

14. Air Lock Valve

3.

Blower 1

15. Fiber Surge Bin

4.

Cyclone Separator 1

16. Hydraulic Baler

5.

Paper Surge Bin

17. Flat Foil Fill, Form

6.

Dosing Device for


Chemical Additive 1

7.

Packaging of the insulation is performed by the fully


automated Hydraulic Baler & Bag Form, Fill and Seal Unit.
Dust collection takes place effectively by separating the
process air from the material flow by the Cyclone
Separators and by leading the air through the selfcleaning Dust Filter Unit.

Dosing Device for


Chemical Additive 2

8.

Chemical Blower

9.

Trash Separator

2.

18. Belt Conveyor


19. Dust Filter Unit
20. Piping
21. Electric Control

System

10. Blower 2

23. Chemical Pulverizer

11. Fiberizer Model 42

24. Spark Detection

12. Blower 3

As options, the system can be equipped with a Chemical


Pulverizer for improving the fire retardant properties of
the chemical additives and with a Spark Detection &
Extinguishing System for improved safety of the plant.
1.

and Seal Device

(Option)

& Extinguishing
System (Option)

(22. Spare Parts)

5.

6.

7.

23.

11.

Fibretec 2000

-automated advanced system19.

20.

Effective capacity:
4.
21.

Required space:

15.

~ 450 m2 + ~ 600 m2

for storing the raw material and final product.

5.

9.

12.
11.

3.

2000 kg/h x 16 h/day~ 25600 kg /


day (with 80 % work time efficiency)

14.
10.

2.

Technical Data

13.

24.

1.

16.

6.
8.

7.
17.

23.
18.

Free height of the hall:


min. 9000 mm
Power supply:
Voltage: 400/230 V, 50 Hz

Connected power ~ 425 kW (without optional items)


Compressed air supply:
Pressure Min 0,6 MPa - Max 0,7 MPa
Quantity ~ 600 l/min
Water supply (only with optional item 24):
Pressure Min 0,2 MPa Max 0,6 MPa
Operators:
2 persons per shift
Other equipment:
1 fork lift
1- 2 hand pallet trucks

2000 kg/hour
~135 bags/hour

Packaging
16.

17.

19.

21.

Plastic foil:
width of foil roll 1450-1500 mm
foil thickness
70 110 m
Size of finished bag:
length
780-800 mm (adjustable)
width
380-400 mm
thickness
325-350 mm
weight
13 - 15 kg (adjustable)
accuracy
+/- 0,2 kg

Green Technology
Fibretec Production Lines
Makron Cellulose Insulation Technology provides
a turnkey package of equipment and services for
manufacturing cellulose insulation from recycled newsprint.
The Makron supply includes all the machinery, piping,
cables as well as the electric control system needed for
the processing plant. The services include supervision for
installation and start-up and also training of the customers
personnel. Furthermore, Makron can assist the customer in
many questions related to the end product know-how.
Combined experience and know-how
Since 2010 Makron has had a strategic alliance with
Reynolds Engineering & Equipment, Inc., based in
Muscatine, Iowa, USA. Reynolds is the leading manufacturer
in North America of Fiberizers, Chemical Pulverizers and
other equipment for the production of cellulose insulation.
Today , the technology of the Makron supply is based on
the combined know-how of both of these experienced
companies.

WALLS:
Density
30 - 35 kg/m3
Exterior and
interior walls
(spray on method)

Density
40 - 50 kg/m3
Vertical hollows
(dry blowing method)

FLOORS:
Density
30 - 40 kg/m3
ATTICKS:
Density
25 - 30 kg/m3
CEILINGS:
Density
40 - 50 kg/m3

The following amounts of raw materials are


needed for producing 1000 kg cellulose fibre
insulation, approx.:
800-900 kg recycled paper (sorted, dry newsprint)
50-100 kg boric acid (H3BO3)
50-100 kg borax decahydrate (Na2B4O7*10H2O),
or borax pentahydrate (Na2B4O7*5H2O)
70 paper or plastic bags for packaging

Why Cellulose Insulation?


Convert a House into a Carbon Sink!
Properties of Cellulose Insulation

Use of Cellulose Insulation

Ecological significantly lower embodied energy than


in fiberglass or rockwool insulation
Self sealing insulation material, minimizes unwanted air leaks
Excellent thermal insulation value
Excellent acoustic properties, too
Breathing material evens out the moisture in the structures
Fire safe does not catch, propagate or spread fire
Resists rot, fungi growth and pests
Strong adhesion to the surrounding structures
Manufactured locally from recycled paper
User friendly installation safe, no cutting, no waste

The usual installation methods of cellulose

Demand for Sustainable Building Products is


Increasing
With cellulose fibre insulation it is possible to convert a house
into a carbon sink. Cellulose insulation is an ecological and
economical thermal and acoustic insulation material, for both new
and renovated buildings. It is a green material manufactured from
recycled newsprint. Non-toxic natural minerals are used to protect
the insulation material against fire and rot.
Thermal conductivity: ~0,040 W/mK.
(Actual -values determined and approved by local authorities)

Fire endurance: Cellulose bre does not maintain or spread re.


(Actual classication according to local requirements)
Air conductivity 80120 x 10-6 m3/msPa,
depending on the installed density

insulation are blowing and spraying, therefore the


result is a seamless insulation that fills perfectly
the entire cavity. Blowing and spraying methods
in installation ensure that the adhesion of the
insulation to the structures will remain unchanged
over the years.
Cellulose fibre insulation can be installed
manually or with specialised blowing or spraying
machines. Due to the convenient installation
method no cutting of the insulation material is
needed.
Blowing method is commonly used on horizontal
and diagonal structures, e.g. on attics and floors, and
on closed walls. The dry insulation material is blown
into the cavity in question. The fine graded material
penetrates well even the small holes and fills exactly
and seamlessly the entire cavity.
Spraying method can be used on vertical
structures,e.g. on walls. The insulation material is
moistened with fine water dust while it is sprayed
onto the open structure. A seamless and draughtfree insulation layer is achieved even in narrow and
complicated places. After drying the insulation is
well adhered to the surrounding structures, which
prevents separation from the structures.

Better Technologies to Build Better

Makron Technology from Finland


Makron Engineering is well known
as a reliable and competitive
supplier of manufacturing solutions
to the timber house and insulation
industry. Today Makron supplies
technology and equipment
for manufacturers of cellulose
bre insulation, log homes and
prefabricated timber houses.
The premises of Makron are located
in Hollola, Finland.

Makron Oy
Vanha Messilntie 4

FI-15860 HOLLOLA,
FINLAND

Tel. +358 3859 500

makron@makron.com
www.makron.fi

Log House Production Lines


Timber Frame Panel Lines
Cellulose Fibre Production Lines

Total Tervice Concept


Makron experts provide the
customers with the total service
concept that covers design,
machine manufacture, supplies,
installation and start-up, training
and maintenance. A guideline
to our service is an investment
study, which targets to improve
our customers competitiveness,
production capacity and quality.
Contact Makron Experts
and Succeed with
Green Technology