GFRP Rebar Production Line

Revolutionizing FRP Rebar Production: Zhongsheng Launches High-Efficiency 5-Line Pultrusion Equipment

The global demand for Fiber Reinforced Polymer (FRP) rebar is skyrocketing. As traditional steel rebar faces severe corrosion issues in marine structures, tunnel linings, bridge decks, and civil engineering, high-strength, lightweight, and corrosion-resistant composite rebar has become the ultimate alternative.

However, for composite manufacturers, the core pain points of traditional FRP rebar production have always been high labor costs, slow single-line output, and inconsistent product quality. To address these challenges, Henan Zhongsheng Composite Materials Co., Ltd. (www.frpzs.com) has introduced its flagship 1-out-of-5 FRP Rebar Pultrusion Production Line—a heavy-duty, fully automated system designed to scale your factory’s output up to five times with minimal footprints.

1. Streamlined 42-Meter Automated Production Process

The Zhongsheng 5-line fiber rebar machine spans a total length of 42,000 mm (42 meters), integrating every stage of composite pultrusion into one continuous, intelligent workflow:

Yarn Creel → Resin Impregnation → Winding & Surface Wrapping → Intelligent Curing → Traction → Auto Shearing

• Yarn Creel (Raw Material Preparation): Featuring a modular 5-layer creel system capable of holding 300 yarn packages simultaneously, ensuring continuous fiber supply without frequent downtime.
• Precision Impregnation (Resin Bath): A heavy-duty, 40L stainless steel resin tank designed with an ultra-wide bottom. Fibers undergo pre-heating and tension adjustment, passing through multi-stage tension rollers to ensure 100% thorough resin wet-out while scraping off excess resin.
• Dual-Workstation Surface Winding: Features high-speed winding heads (0-400 r/min) synchronized in real-time with the traction speed via variable frequency drives to wrap polyester fibers tightly around the core.
• Intelligent Heating & Curing: A massive 11.25-meter curing oven split into 5 independent heating zones (9kW each, total 45kW). Pneumatic controls allow easy opening, while the heating plates and hot air circulation guarantee uniform temperature mapping from 0°C up to 250°C.
• Continuous Traction: Driven by a high-torque variable frequency drive delivering 20kN of traction force.
• Smart Length-Counting & Shear: Automatic meter-counting system triggers precise flying shears, delivering finished rebars to the automatic unloading flip-rack.

2. Technical Breakthroughs: Why Choose Zhongsheng’s 5-Line Equipment?

Traditional multi-line machines often suffer from fiber twisting, tension imbalance, and product deformation. Zhongsheng overcomes these limitations through patented engineering breakthroughs:

• 5-Line Independent Caterpillar Traction & Speed Control

Unlike traditional pultrusion systems where all lines share a single puller, Zhongsheng features 5 groups of independent caterpillar haul-offs. Each line is individually driven and speed-regulated, allowing you to run different rebar diameters (from Φ4mm up to Φ32mm) simultaneously without any cross-interference. The caterpillar blocks are made of ultra-wear-resistant polyurethane (Shore hardness ≥85), protecting the rebar's ribbed surface from damage.

• Closed-Loop Resin Impregnation (Environmentally Friendly)

To meet strict global environmental regulations, Zhongsheng offers optional closed-loop unsaturated/epoxy resin injection systems. Unlike open baths that release heavy VOC emissions, this closed-loop system reduces resin waste, lowers VOCs, increases fiber volume fraction, and ensures high-consistency mechanical properties.

3. High ROI: Capacity & Daily Output Analysis

For plant managers, production data translates directly into profit. The Zhongsheng 5-line machine handles a versatile production range of Φ4mm to Φ32mm. Below is the actual performance data showcasing daily yield (calculated based on an effective 1,300 minutes/day runtime):

About Zhongsheng Composites

As a premier turnkey composite manufacturing solution provider, Henan Zhongsheng integrates advanced equipment R&D, high-precision pultrusion molds, profile customization, and technical output. All pultrusion molds feature laser-quenched cavities (hardness ≥ HRC60) and micrometer-level progressive grinding to ensure exceptional durability and zero surface defects on finished profiles.