SUNTHERM Ceramic Fiber Blanket Production Line

Product Overview

Using high-purity aluminum oxide and silicon dioxide as primary raw materials, the ceramic fiber blanket production line integrates multiple processes including high-temperature melting in electric or gas furnaces, centrifugal fiberizing, needle-punching into blankets, shaping and cutting, and automatic winding. The final products are eco-friendly ceramic fiber insulation materials featuring high-temperature resistance, low thermal conductivity, excellent flexibility, and asbestos-free composition.

This equipment system is widely used in refractory material plants, insulation product manufacturers, and enterprises in industries such as steel, petrochemicals, building materials, metallurgy, and power generation. It plays a key role in enhancing both the production efficiency and product quality of high-temperature insulation materials.

Equipment Structure & Components

A complete ceramic fiber blanket production line generally includes the following core sections:

(1) Raw Material Feeding System

Bucket elevators and batching weigh systems

Automated feeding into the melting furnace to ensure precise composition ratios

(2) High-Temperature Melting System

Electric arc or natural gas melting furnace with refractory lining

Temperature control system accurately maintains melting temperatures between 1700°C and 1850°C

(3) Fiber Forming System

Fiberizing machine equipped with multi-disc high-speed centrifugal rotors

Hot air assist system for efficient blowing and spinning

Produces uniform fibers with diameters controlled within 2–5 μm

(4) Web Formation & Layering System

Negative pressure suction chamber and conveyor belt for even fiber deposition

Adjustable parameters for thickness and density during forming

(5) Double-Side Needle-Punching System

Upper and lower needle looms with adjustable punching density

Enhances blanket strength, structural stability, and flexibility

(6) Drying & Curing System (Optional)

Thermal setting for hydrophobic or surface-bonded fiber blankets

Gas or electric heating options available

(7) Edge Trimming & Cutting System

High-speed precision cutting machines

Ensures consistent product dimensions and neat edges

(8) Winding & Packaging System

Automatic winding machine with length control

Configurable roll diameter and weight, supports online packing

(9) Electrical Control System

Automated PLC and HMI-based control

Integrated management of parameter setting, data logging, and fault alarms

Process Flow Diagram

Batching → Melting → Fiberizing → Web Formation → Needle Punching → Drying & Curing → Cutting → Winding → Packaging

Main Technical Parameters

Project	Parameter Range	Illustrate
Annual production capacity	1000~5000 tons/year	Customized according to customer needs
Production line width	600~2400 mm	Support customized wide format equipment
Blanket thickness	6~100 mm	Typical specifications are 10/20/25/50 mm
Finished product density range	64/96/128/160 kg/m³	Support multi-density product switching
Fiber diameter	2~5 μm	The smaller the fineness, the better the thermal insulation effect
Control system	PLC+touch screen	Siemens or domestic brands available
Total installed power	300~800 kW	Electricity/gas dual energy adaptation
Floor space	1500~4000 m²	According to the actual line length and configuration
Number of operators	4~6 people/class	High degree of automation

Product Features & Advantages

(1) High Production Efficiency

The fully automated production line operates continuously from raw material melting to finished product, achieving a maximum daily output exceeding 20 tons.

(2) Stable Product Quality

The process ensures uniform fiber fineness and consistent blanket density, delivering excellent flexibility, thermal shock resistance, low thermal conductivity, and high performance uniformity.

(3) Multi-Product Compatibility

The line supports production of various ceramic fiber blanket types, including standard, high-purity, hydrophobic, and zirconium-enhanced grades.

(4) Energy-Saving & Eco-Friendly Design

Featuring optimized furnace insulation and energy recovery systems, the line significantly reduces energy consumption and complies with environmental standards.

(5) Remote Monitoring & Smart Diagnostics

Optional Industrial IoT modules enable real-time remote monitoring of equipment operation and proactive maintenance diagnostics.

Typical Application Scenarios

Ceramic fiber blankets produced by the line are widely used in high-temperature applications including:

✓ Industrial kiln linings (tunnel kilns, electric furnaces, heat treatment furnaces)

✓ Insulation wrapping for high-temperature pipelines, elbows, and flanges

✓ Thermal insulation for metallurgical hot blast stoves, ladles, and electrode covers

✓ Insulation linings for petrochemical reactors and heat exchangers

✓ Power generation boiler walls and hot air ducts

✓ Automotive exhaust system heat shields

✓ Aerospace engine thermal protection components

Production Line Configuration Proposal

Production line scale	Applicable enterprises	Annual production capacity range	Typical configuration features
Small experimental line	Scientific research/high temperature material development	300~800 tons	Manual adjustment, suitable for trial production of new products
Standard medium-sized production line	Conventional insulation material manufacturers	1000~3000tons	Automatic winding, needling, cutting and supporting packaging lines
Large-scale production lines	High-end industrial park/foreign trade factory	3000~5000tons	Compatible with multiple production types, equipped with automatic tool changing system, etc.

Investment and Return Analysis

Initial Investment: Approximately RMB 3-8 million, depending on scale, process requirements, and the degree of supporting automation;

Operating Costs: Primarily energy, labor, and maintenance costs;

Payback Period: Approximately 12-24 months under normal operation;

Profitability: Flexible adjustment of output specifications based on market demand to increase gross profit margin;

Scalability: Modular design facilitates future production increases or product line expansions.

After-Sales and Technical Services

Free technical training and equipment installation guidance;

One-year warranty and lifetime technical support;

Equipment operation optimization recommendations and process upgrade services;

24/7 after-sales response system;

Spare parts supply and customized maintenance plans available.

FAQ

Q1: What types of ceramic fiber blankets are suitable for this production line?

A1: This production line supports standard, high-purity, zirconium-containing, and hydrophobic ceramic fiber blankets, and supports rapid switching between different densities and thicknesses.

Q2: How many people are required to operate this production line? A2: The entire line is highly automated, typically requiring only 4-6 people per shift, including controllers, furnace operators, quality inspectors, and packagers.

Q3: How is fiber dust contamination controlled?

A3: Equipped with a high-efficiency dust removal system, sealed exhaust hood, and dust collection bags, the system provides a high dust recovery rate and complies with environmental regulations.

Q4: How long is the installation period?

A4: Depending on the scale of the equipment, installation and commissioning generally take 30-60 days, including training and pre-production commissioning.

Q5: Does it support export?

A5: Yes, we have successful export experience to Russia, Turkey, India, Vietnam, Brazil, and other countries.

Q6: Can you provide customized solutions?

A6: Yes, we can provide customized designs and complete line layouts based on customer production capacity, process, budget, and other requirements.

Ceramic fiber blankets, essential insulation materials for modern high-temperature industries, are experiencing continued market demand. An efficient, stable, and highly automated ceramic fiber blanket production line is crucial for enhancing a company's core competitiveness. We not only provide sophisticated production line equipment, but also offer one-stop services from selection, design, installation, and operational support to help you achieve efficient, safe, and sustainable production of thermal materials.

Please contact us for technical solutions, detailed quotes, and on-site video examples.

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