Rock wool production line

A complete rock wool production line consists in several machines that process the material, from melting to packaging. The “hot” part is located at the beginning of the line where the machine melts the basalt rock and transforms it into fibre. The polymerisation and material processing stages follow, where the product takes on its final shape (panels, mattresses or felt). The packaging system is located at the end of the line and consists in machines that package the product and prepare it for warehousing or shipment. For “special” products such as pipe section or lamellar products, Gamma Meccanica supplies special systems or “additional lines".

 

The indicative production capacity of a rock wool line can vary from 200 – 1500 kg/h with tank melters, from 1000 - 6000 kg/h with cupola melters and from 1000 - 6000 kg/h with electric melters.

 

Product specifications can vary according to the customer’s requirements. The working widht of a production line can vary from 1200 – 1800 – 2000 – 2400 mm.

Wool production

Rock wool is obtained by melting and transforming basalt rock. A complete rock wool system consists in a machine assembly, which carries out the transformation process. The first stage of the process consists in the storage and melting of the rock to be transformed into wool. The machines that make up this part of the line generally include: raw material storage, mixing and feeding system; a melting system and fibre forming. The latter transforms the melted material into fibre by means of a centrifuge.

 

Material formation

This stage is fundamental to achieve good quality end products.
The fibre feeding/distribution system and polymerisation oven are the most important machines in this part of the line.

 

Smokes and dust filtration systems
To safeguard the environment, Gamma Meccanica has always given priority to developing and providing its lines with efficient systems to filter and treat the gases and residues which can be produced during the transformation process. 

 

Processes and final product

After the polymerisation process, the rock wool is ready to be transformed into panels or rolls. On leaving the polymerisation oven, the material is trimmed. The trimmings are automatically recovered and returned to the production process.
The rock wool can be faced or coupled in line with other materials (aluminium, kraft paper, glass veil). A rock wool line includes cutting systems and cutters to define the length and width of the panels or rolls.

 

Packaging systems

The production process ends with the material packaging phase: Gamma Meccanica proposes several solutions to pack the end product in order to satisfy different market requirements.

 

 

Rock wool products

 

Polymerised felt
Density 30 - 45 Kg/m3
Thickness 40 - 120 mm
Width 600 – 1000 - 1200 mm
 

 

Boards
Density 35 - 220 Kg/m3
Thickness 20 - 200 mm
Width 400 - 600 – 1000 - 1200 mm
 

All products (except mattresses) can be faced with various types of materials (depending on their use), such as paper, aluminium, glass veil. 

 

Stitched mattresses
Density 65 - 125 Kg/m3
Thickness 40 - 120 mm
Width 600 -1000 - 1200 mm