Complete Extrusion Lines for Plastic Pipes

7/27/2019 Complete Extrusion Lines for Plastic Pipes

http://slidepdf.com/reader/full/complete-extrusion-lines-for-plastic-pipes 1/12

Complete ExtrusionLines for Plastic PipesValue Through Know-How

Hyvä imagollinen kuva tehtaalta.



Delivering Know-How:Extrusion Lines by Pipe ManufacturerThe 50 years of experience in designand manufacTuring of plasTic pipeexTrusion lines ensures successfulsoluTions for every cusTomer.Being also a pipe manufacTurer,we consTanTly sTrive for newinnovaTions in Terms of qualiTyand producTiviTy.

As we pass on this know-how to the customers. Whois not only getting the best technology, but a business-ready, complete production concept. Our heavyduty extrusion lines enable the production of severaldifferent products like tap water, gas, PE casing pipes,heating pipes, meaning the capacity can be adoptedto where needed at the time.

KWH Pipe Technology provides complete extrusionlines for PE-HD pipe manufacturing in dimensionsranging from 16 up to 1600 mm. In addition, we alsosupply PP-r and PEX –pipe manufacturing equipment.

Cooling bath

Extruder Diehead with dieand mandrel

Calibrator

Cutting unitHaul-offRaw material hopper

E l e c t r i c

m o t o r

Warm zone Cold zone





Ef cient Raw Material HandlingRaw material handling system is designed to transferraw materials to the feed hopper of the extruder andto keep the manufacturing process continuous. Thesystem comprises the following components:

• Vacuum conveyor, which transfers raw materialgranulate from the storage bunker to the feedhopper of an extruder, or alternatively to anoptional dryer.

• An optional raw material dryer completed with avacuum conveyor, which transfers raw materialgranulate from the dryer to the feed hopper of theextruder. Tubes for transporting of raw materialare of stainless steel. Air ducts of the raw materialtransfer system are of aluminum alloy.

Gravimetric control system (GCS) monitors the rawmaterial consumption in real-time mode and comparesit to the haul-off speed. If any deviation of actual

metric weight from its calculated value occurs, GCScorrects the speed of the extruder or the speedof the haul-off unit. According to the Customer’sdemand and requirements, the GCS instrumentationand software are delivered either for single- ow ormulti- ow monitoring. A basic GCS is comprised offollowing components:

• feed hopper• weighing hopper• metering valve and frame

• PLC with single user interface• line speed measurement with closed loop control• screw rotary speed measurement

• measurement of screw output per one revolution(gr/r)

• interfaces for upper level control and printer(optional)

Real-Time Monitoring,Real-Time Value

RAW MATERIAL HANDLING SYSTEM

TYPE Type 1 Type 2 Type 3 Type 4

c t k / 500 1000 1500 2000



Single Screw ExtrudersThe pipe extruder is designed for the manufacturingof polyole n pipes. The product range comprisesextruders with screw diameters from 18 to 150 mm.

• Barrier screw: Nitrated steel, HV 950 – 1000• Grooved feed bush: used with a barrier screw

enables high plasti cation rates and low melttemperatures

• Extruder barrel: Nitrated steel, HV 950 - 1000• Temperature control zones, heating/cooling• Heating zones of extrusion die ange.

Diversi ed Extrusion ToolsThe KWH pipe extrusion dies enable pipe extrusionof polyole n materials, such as PE (HDPE, MDPE)and PP. The die-heads are of spiral distribution type.Dimensioning of the ow channels is based on therheological characteristics of the most frequentlyused types of plastics. Optionally the die head can beequipped with Internal Cooling System for shortencooling length or increasing output.

The Advantages:

• low head volume enables short dwell times andlow thermal stress impressed upon the melt

• low pressure build-up even at high materialthroughput at low stock temperature• precise distribution of the melt which minimizes

the wall thickness deviations• short self-cleaning time when changing the colour

of raw material• high mechanical characteristics of the pipe.



Save Energy, Produce More:High Performance 37 L/D ExtruderHigh output 37 L/D extruder series for the demands ofenergy saving and constant distribution.

Standard water-cooled AC -motor:

• Excellent coef cient of ef ciency (92,9 %).• Low noise level <75 dB(A), without heat losses to

the production hall.

Energy saving water-cooled drive:

• The intelligent frequency converter adjustsmagnetization according to the load, which meansimproved ef ciency.

Advanced barrel cooling:

• Cooling ns and ceramic heaters ensures accuratemelt temperature. Internal cooling of the screw isoptionally available.

Constant output:

• Spiral grooved feed section creates circumstancesfor formation of even constant and homogenoushigh output of the melt ow.

Closed loop cooling system:

• Extruders provided with closed cooling system havewater-cooled motor, drive, control cabin, gear andbarrel. Internal screw cooling as option.

• The system is silent with no heat losses to theenvironment.

• It is easy to connect to the factory’s cooling systemor process water. Due to glycol composition theclosed system remains clean and rustless.

Movable operator control panel and Internetremote connection:

• Mobile control panel can be moved either side ofthe extruder or even near to pipe head.

• Multilingual selected by push button.• The PLC includes Ethernet for the remote

connection by VPN router or internet connectionwith customer’s accessible I.P. Address.

Mixer (Option):

• The mixer ensures huge increase of output andhomogenous melt with even distribution fordifferent kind of master batches. The hemisphericalcavities of the mixer force the raw materialtravelling along the barrel continuously changingdirection, causing shearing and cutting action tothe melt.





Advanced Calibration ToolsCalibration gives the pipe its nal shape and size.KWH provides complete range of calibration sleevesfor vacuum and pressure calibration. Our longexperience in pipe manufacturing allows precisedesigning of the sleeves that optimizes production.High quality calibration tools ensure round pipes withexcellent surface and lower overweight of the pipeproducts.

Pipe Calibration Tanks

The calibration tank can be either of single or double

chamber construction. The bottom part of the unitis used as a water reservoir, which ensures precisetemperature control in the calibration tank. Thetemperature of the calibration tank is kept on thedesired level by a thermostat. The calibration tank isinstalled on the rail tracks, anchored to the workshop’s

oor. The longitudinal movement of the calibrationtank is motorised.

Haul-off unit

The haul-off unit grips the pipe over a long length andpulls it at a constant speed. The haul-off consists of anumber of pulling belts around the pipe. The pullingbelts, which are located under the extrusion axis, aremechanically adjustable and upper ones are drivenpneumatically.

Pipe cutting equipment

Pipes with a diameter over Ø 160 mm are usually cutto the standard length.

Circular saws

Circular saws for cutting pipes of outer diameter up toØ 250 mm.

Planetary saws

The planetary saw is delivered as a single cut unit. Byrequest any planetary saw can be equipped with two-step cutting heads. The initial cut is executed by disksaws and the nal operation by cutting blades. In that

way ingress of sawdust inside the pipe is prevented.

Vacuum Calibration Tanks

TYPE VCA63-6

VCA110-6

VCA250-6

VCA400-6

VCA630-6

VCA800-6

VCA1200-6

p t Ø, 10 - 63 20 - 110 50 - 250 63 - 400 110 - 630 250 - 800 630 - 1200

Spray Cooling Baths

TYPE SB 63-10(6)

SB 110-10(6)

SB 250-10(6)

SB 400-10(6)

SB 630-10(6)

SB 800-10(6)

SB 1200-10(6)

SB-1600-6(4)

p t Ø, 10 - 63 20 - 110 50 - 250 63 - 400 110 - 630 250 - 800 630-1200 710-1600

Pressure Calibration Tanks

TYPE PCA1200

PCA1600

p t Ø, 400 - 1200 710-1600

Haul-Off Units

TYPE PVL 110/3 PVL 250/4 PVL 400/6 PVL 630/6 PVL 800/6 PVL1000/8 PVL 1200/10 PVL 1600/12

p t Ø, 16 - 110 50 - 250 40 - 400 110 - 630 140 - 800 160 -1000 315 - 1200 710 - 1600





Full Process ControlThe control system constantly monitors themanufacturing process on its every stage and correctscurrent production parameters to the set value. Basiccontrol system provides following services to themanufacturing process:

• Speed control of all installed drives of theproduction line

• Temperature control and adjusting to the set point• Control of water level in calibration tanks and spray

cooling baths

• Pressure control of raw material melt• Raw material ow control• Alarm reporting and diagnostics.

Integrating the gravimetric control into the basiccontrol system enables enhanced process monitoringand run mode optimization, saving raw materials andother resources.

Extended operation control system

The operation control system of a single extrusionline can be connected to the PC-based upper levelcontrol system, which integrates and administerscontrol systems of all installed production lines of thefactory. This enables effective and comprehensiveprocess control, including operation security and co-ordination. The extended operation control systemallows the manufacturing process automation.

Wall thickness ultrasonic measure control (UMC)

The wall thickness ultrasonic measure control is tomaintain the high and stable product quality and tominimize consumtion of speci c raw materials. Thecore of the ultrasonic measure control system is thehigh-speed ultrasonic evaluation electronics and thesensor system. The processed data is displayed on theUMC output screen and used by the process controlsystem to correct the performance of the extrusionline.

The UMC controls the following operations andrelated parameters:

• metric weight (haul-off / extruder)• minimum wall thickness (haul-off)• wall thickness pro le (die head centering)• diameter (vacuum)• extruder/start-up ramps• component dosing• co-extrusion.



AftersalesKWH provides services by our skilled and professional staff.Our customer service offers original spare parts with exibleand short delivery times.Customers’ staff is trained in Finland and during the startup at the customers’ premises. Our experienced techniciansassists and helps you to maintain best quality products inyour manufacturing line.We invest time in understanding the customer andprovide top-class service from start to nish.Our customers’ success is our success



Kwh p T t t t

t t . Kwh p T t tKwh p g , t

t t t t t e , n t a

s t a .s t 1960´ , t T

t t Kwh p b t t

t t .Kwh p T

tt

t tt k t

j t .

KWH Pipe Ltd, Technology

P.O. Box 383

FI-65101 Vaasa, Finland (Head of ce)Tel. + 358 6 326 5511Telefax +358 6 326 5690E-mail: [email protected]

Professional Solu-tions for PlasticsIndustry

Documents

Complete Extrusion Lines for Plastic Pipes