The production process for ESPC wall panels requires a closed-loop environmental approach encompassing seven key dimensions: raw material selection, production process optimization, mold design improvements, production equipment upgrades, pollutant emission control, waste recycling, and an environmental certification system. This ensures a pollution-free process.
Raw material selection is the foundation of environmentally friendly production. The core base material of ESPC wall panels is calcium carbonate (CaCO₃), a natural inorganic compound found in rocks such as limestone and marble, and known for its zero formaldehyde emissions. The surface layer utilizes PET (polyethylene terephthalate), a food-grade packaging material. Its non-toxic, odorless, and weather-resistant properties ensure excellent indoor air quality. The digital painting layer utilizes six-color digital printing technology, replacing traditional solvent-based inks with water-based pigments to eliminate volatile organic compound (VOC) pollution at the source.
Production process optimization focuses on low-temperature molding and physical modification techniques. By adjusting the ratio of calcium carbonate to high-molecular-weight polymer, a co-extrusion process allows for the integrated molding of the base and finish layers, eliminating the use of adhesives. The digital painting process uses a Swiss SEITZ 160-megapixel camera to capture natural textures. Combined with six-color reproduction technology, high-precision patterns are created on the stone crystal substrate, reducing waste discharge associated with traditional printing processes. The nano-silver antibacterial coating is applied through physical deposition, eliminating the need for chemical plating and eliminating heavy metal pollution.
Improved mold design significantly reduces production energy consumption and waste. The enclosed mold structure reduces dust emissions by over 30%. Combined with an intelligent exhaust system, it ensures smooth air bubble removal during pouring, improving product density and reducing scrap rates. The use of special wear-resistant steel extends mold life by twice that of traditional molds, reducing mold replacement frequency and waste generation. The multifunctional modular mold design accommodates various size requirements, allowing one mold to produce ESP wall panels of varying specifications, reducing mold development and resource consumption.
Upgrading production equipment is key to achieving clean production. The enclosed mixing equipment utilizes a negative pressure suction system to prevent dust pollution during the raw material mixing process. The environmentally friendly release agent uses plant-based ingredients instead of mineral oil to reduce the release of harmful chemicals. High-efficiency dust removal facilities equipped with pulse backflushing devices capture over 99% of micron-sized particles, ensuring dust concentrations in the workshop are below 8mg/m³. A waste recycling system crushes and grades scrap materials for reuse in substrate production, achieving a closed-loop resource utilization.
Pollutant emission control is implemented throughout the entire production cycle. Wastewater treatment utilizes a combination of physical precipitation and biodegradation to ensure a chemical oxygen demand (COD) below 50mg/L. Exhaust gas emissions are treated through activated carbon adsorption and catalytic combustion, reducing non-methane hydrocarbon concentrations to below 20mg/m³. Low-speed equipment and soundproof enclosures are used to control workplace noise levels to below 85dB.
A waste recycling system fosters a green supply chain. Production waste is crushed and screened, then graded by particle size for use in the production of ESPC wall panels of varying strength grades. Biodegradable kraft paper and honeycomb cardboard are used as packaging materials instead of foam plastics, and recyclable turnover racks are used in transportation to reduce disposable packaging consumption. We have established a cooperative mechanism with downstream recycling companies to chemically decompose scrapped ESPC wall panels, recycle calcium carbonate and polymer materials, and form an industrial closed loop.
