Polyester · UPR

Polyester
casting line

Name: Polyester casting and mixing line POLYBLENDER®
Brand: POLYBLENDER

// Polyether metering & mixing system

Continuous metering and mixing of unsaturated polyester resin with mineral fillers. The most widely used binder system in cast stone worldwide: the raw material is available almost everywhere and the finished part is the least expensive of the four systems.

Request a quotation → How the line works

4–16 kg/min

Output of lines in service

2:1 … 1:2

Metering ratio

3000 rpm

Mixing head

0.1 mbar

Vacuum degassing

POLYBLENDER polyester casting line, complete unit with filler feeders, mixing head and control cabinet

Shared platform

How the line works

All four binder systems run on one machine design. The five stages work as a single flow; what changes between configurations is the binder, the materials of the wetted parts, the temperature regime and the casting programme.

Dry component metering

Screw feeders for coarse and fine mineral filler with an active bridge-breaking device, WIKA level sensors and a replaceable filter cartridge on every hopper, so dust is not vented into the workshop.

Liquid component metering

Separate pump groups for resin and hardener: BAUTEC gear pumps, FESTO servo drives, pressure monitoring on each line, automatic recirculation when the machine stops.

Dynamic mixing head

Recirculation-type low-pressure head with a Siemens drive, a horizontal traverse unit for calibration and servicing, and automatic solvent flushing after every cycle.

Vacuum degassing

Degassing column with a BUSCH R5 rotary vane pump, residual pressure 0.1 mbar. Air entrained during mixing is removed before the mix reaches the mould.

Casting and control

Casting unit, 12″ touch panel, a frequency converter per metered component, recipe memory and remote diagnostics over WIFI.

Specification

Technical data

Polyester line · POLYBLENDER®
Output of lines in service	4–16 kg/min
Design maximum of the range	24 kg/min, higher on request
Binder system	Unsaturated polyester resin (UPR)
Metering ratio, resin : hardener	2:1 … 1:2
Mixing head	Dynamic, low pressure, Siemens drive, up to 3000 rpm
Vacuum degassing	BUSCH R5 column, residual pressure 0.1 mbar
Resin buffer tank	170 l, carbon steel, with continuous agitation
In-line resin heater	7.5 kW, WIWA, PID temperature control
Colour lines	Up to 4 simultaneously
Control	12″ touch panel, mobile pendant, remote diagnostics over WIFI
Bought-in components	Siemens, BAUTEC, FESTO, WIKA, BUSCH, Mitsubishi Electric, DuPont TEFLON and VITON
Supply basis	Built to the customer’s technical specification

There is no fixed model range and no price list. Unit layout, output and automation follow the customer’s technical specification, and the quotation is prepared once that specification is agreed.

// Applications

Cast stone on a polyester binder

Polyester is the entry point into cast stone: the widest raw material availability and the lowest part cost of the four systems.

Solid Surface sheet Cast marble Kitchen worktops Sinks and washbasins Bathtubs Stone slabs Façade panels Floor tiles Onyx and travertine imitation

Casting unit of the POLYBLENDER polyester line discharging the mix into a mould

Reference installation

Reference: sanitaryware producer, north-west Russia

A manufacturer of premium cast stone sanitaryware runs the polyester and acrylic configurations of this line at a single site: sheet casting followed by milling, seamless bonding, sanding and edge lighting, with no intermediate processing bought in.

The plant belongs to the equipment manufacturer, which is the practical difference from a trading company: commissioning and operator training are delivered from a working shop floor rather than from a translated manual.

FAQ

Questions and answers

What is the output of the polyester line?

Output is set by the technical specification. Lines currently in service run between 4 and 16 kg/min of finished mix; the design maximum of the range is 24 kg/min, and higher figures are calculated on request.

Why does the mix need vacuum degassing?

Air is entrained into the resin during mixing. Without degassing it stays in the casting as voids and pinholes on the visible surface. The column brings residual pressure down to 0.1 mbar before the mix reaches the mould.

What causes filler settling and a cloudy matrix?

An unbalanced formulation. Too much resin lowers viscosity and the filler settles before gel time; too little makes the matrix viscous and it entrains air. Continuous metering with recipe control removes both effects that manual batching cannot.

What can be produced on this line?

Solid Surface and cast marble: worktops, sinks and washbasins, bathtubs, stone slabs, façade and floor panels, onyx and travertine imitations.

Is there a fixed model range and a price list?

No. Every line is engineered and built to the customer's technical specification: the unit layout, number of feeders, output and degree of automation follow the product you intend to make. The quotation is prepared once the specification is agreed.

Which countries do you supply?

China, India, the Middle East, the CIS and Russia. Correspondence and documentation in English or Russian; the control software interface is supplied in the language agreed for the project.

Who manufactures the equipment?

SARMATECH LLC, Leningrad Oblast, Russia, established 1998. The machines carry the AUTOCASTER® mark; the line and its control software carry the POLYBLENDER® mark.

Catalogue

Equipment catalogue