Ceramic Fiber Blanket Production Line

Name: Ceramic Fiber Blanket Production Line
Brand: Jinyuan
SKU: JY-CERAMICFIBERBLANKETLINE
Availability: InStock

Needle loom on ceramic fiber blanket line

A ceramic fiber blanket production line converts alumina-silica raw materials into needled blanket rolls through a continuous chain of processes: batching, melting, fiberising, cotton collection, blanket forming, needle punching, curing, cutting and packaging. The line is the core asset of any ceramic fiber plant, and its configuration determines the fiber diameter distribution, shot content, density uniformity and tensile strength of the finished blanket.

Two fiberising routes are available and the choice drives both capital cost and product grade. Spinning (centrifugal spinning on high-speed rollers) produces longer, finer fibers with low shot content and is the standard route for standard and high-purity blankets. Blowing (high-velocity air or steam jet) is simpler and cheaper to install, but yields shorter fibers with higher shot content, suiting lower-grade bulk and loose-fill applications. We supply both, and will recommend one based on your target product mix rather than pushing a single configuration.

Each line is engineered around four inputs: raw material composition, target blanket density range, finished width and required annual tonnage. From those we size the furnace transformer capacity, the number of spinning heads, the needle loom working width and station count, and the curing oven length. Turn-key delivery covers plant layout design, equipment manufacture, shipping, installation supervision, commissioning and operator training.

Technical Specifications

Annual Capacity	1,000 – 10,000 tons/year
Classification Temperature	1260°C / 1350°C / 1430°C
Blanket Width	610mm / 1220mm (customizable)
Blanket Thickness	6mm – 50mm
Bulk Density	64 – 160 kg/m³
Fiber Diameter	2 – 5 μm
Shot Content	< 15% (spun fiber, non-fibresized)
Melting Furnace Type	Electric arc / resistance (per material)
Fiber Forming	Spinning / blowing (selectable)
Needle Loom Speed	Up to 3.5 m/min
Control System	PLC + HMI + SCADA (remote capable)
Installed Power	From 800 kVA (configuration dependent)
Power Supply	380V/50Hz/3Phase (customizable)

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Process Flow

How a ceramic fiber blanket production line runs from raw material to finished product

Ceramic Fiber Blanket Production Line: Raw Material Batching → Electric Arc Furnace Melting → Fiber Spinning / Blowing → Cotton Collection → Blanket Forming (pendulum laying) → Needle Punching → Curing Oven → Longitudinal Cutting → Transverse Cutting → Rolling → Automatic Packaging → Warehouse

Key Equipment Included

Automatic batching and feeding system
Electric arc melting furnace with water-cooled panels
High-speed spinning machine (or blowing machine)
Cotton collection chamber with cyclone separator
Pendulum blanket forming conveyor
Double-board needle loom (multi-station)
Hot-air curing oven
Longitudinal and transverse cutting system
Automatic rolling and packaging machine
PLC control cabinet + SCADA monitoring
Dust removal and environmental system

Applications

Where the output of this line is used

Industrial Furnace Linings

Hot-face and backup insulation for heat treatment furnaces, forging furnaces, reheating furnaces and ceramic kilns.

Petrochemical Heaters

Lining for reformers, cracking furnaces and process heaters where thermal shock resistance is critical.

Power & Boiler Insulation

Duct, boiler wall and expansion joint insulation in power generation and waste incineration plants.

Why This Line From Jinyuan

Engineering decisions that show up in your daily operating cost

Fiberising route matched to your product mix

We size the spinning section against your real grade split instead of overselling capacity you cannot sell. Spinning and blowing can be combined on one line.

Needle loom built for continuous duty

Rigid welded frame, hardened guide plates and balanced drive shafts keep needle breakage and blanket streaking down over long runs at production speed.

Density uniformity held across the width

Pendulum laying plus weighed feedback on the forming conveyor keeps cross-web density variation in a narrow band, so you are not giving away density to hit the minimum.

Frequently Asked Questions

Common questions before ordering a ceramic fiber blanket production line

What is the difference between a spun and a blown ceramic fiber blanket line?

Spinning throws molten stream off high-speed rollers, producing longer fibers with lower shot content and better tensile strength — the standard choice for blanket grades. Blowing uses a high-velocity jet and produces shorter, shot-heavier fiber, which is cheaper to make but suited to bulk fiber and lower-grade products. The blown route costs less up front; the spun route gives you access to higher-value grades.

How much space does a blanket production line need?

A 3,000 t/y line typically needs roughly 2,500–3,500 m² of covered floor area including raw material storage, melting, fiberising, needling, curing and finished goods warehouse, plus an outdoor transformer and cooling area. We issue a plant layout drawing with the proposal, sized to your actual building.

How long does delivery and commissioning take?

Manufacturing runs about 90–150 days depending on capacity and degree of automation. Shipping, installation and commissioning add another 45–90 days depending on site readiness and visa lead time. We will commit to a schedule in the contract rather than quoting a generic range.

Can one line produce both standard and high-purity blankets?

Yes, provided the melting section and furnace lining are specified for the higher alumina duty. Changing grade between campaigns requires a furnace flush and a settling period. We recommend deciding your grade split during design, because retrofitting a higher-temperature melting section later is disproportionately expensive.

What raw materials does the line consume?

Typically alumina-silica blends — calcined alumina, silica sand, zircon sand for higher grades — melted in an electric arc or resistance furnace. Electrical energy is the dominant operating cost, commonly 1.0–1.6 kWh per kg of fiber depending on furnace design and grade. Ask us for a consumption estimate based on your specific grade mix.

Do you provide installation and training?

Yes. Turn-key delivery includes dispatch of commissioning engineers for mechanical installation supervision, electrical hook-up, process start-up and parameter tuning, plus on-site operator and maintenance training. Remote support continues after handover through the SCADA link.