In the field of wastewater treatment, the moving bed biofilm reactor (MBBR) process is hailed as the “heart” of the biochemical system due to its highly efficient removal of organic matter. As the core of this process—the MBBR biological packing material—its production quality directly determines the water treatment efficiency.

Today, from the technical perspective of Qingdao Fullwin Plastic Machinery, Ltd., we will take you inside the production line of this environmentally friendly “core” material, revealing how it is transformed from raw materials to finished products.

First Stop: Raw Material Supply and Extrusion Plasticization The production line begins with an automatic feeding system.

High-density polyethylene (HDPE) or polypropylene (PP) base resins, combined with hydrophilic materials and bio-enzyme promoters, are conveyed in a sealed manner to the extruder hopper via a vacuum feeder. In the single-screw extruder designed by Qingdao FULLWIN, the material undergoes heating, melting, and shearing mixing to become a uniformly flowing melt. Our screw undergoes special optimization to ensure excellent material plasticization, laying the foundation for subsequent molding.

Second Stop: Mold Forming and Vacuum Sizing

Subsequently, the melt is extruded into a precision molding die. This is a crucial step in determining the shape of the packing material. Depending on customer needs, the mold can be designed with a high-efficiency structure of extruding two, four, or even six cells simultaneously. The cell blanks immediately enter the vacuum forming tank. Under the dual action of vacuum negative pressure and cooling water, the outer diameter of the filler is precisely locked, and the internal fan-shaped or honeycomb structure gradually solidifies, resulting in a smooth and defect-free surface.

The third stage: Traction Cutting and Post-processing.

The fully cooled and formed continuous honeycomb tubes are evenly and stably transported to the cutting area by a tracked traction machine. The Qingdao Fullwin production line is equipped with a servo cutter, capable of precisely cutting the tubes to specified lengths (typically cylindrical particles with a diameter or length of approximately 1 cm).

Fourth Station: Finished Product Inspection and Packaging

These tiny fillers have an extremely large specific surface area (up to 3.125 cm²/mL) and a density close to water, allowing them to flow rapidly and fluidize in the aeration tank, providing an ideal attachment site for microorganisms.

The MBBR filler extrusion production line provided by Qingdao Fullwin Plastic Machinery Co., Ltd. achieves fully automated control throughout the entire process, from automatic feeding, high-efficiency extrusion, vacuum sizing to high-speed cutting.

We not only provide equipment, but also customize complete production process solutions based on your raw material characteristics and production capacity requirements, helping to upgrade environmental protection equipment manufacturing!