Complete Extrusion Lines for Plastic Pipes

Value Through Know-How

Hyv imagollinen kuva tehtaalta.

About U

Delivering Know-How:
The 50 years of experience in design and manufacturing of plastic pipe extrusion lines ensures successful solutions for every customer. Being also a pipe manufacturer, we constantly strive for new innovations in terms of quality and productivity.
As we pass on this know-how to the customers. Who is not only getting the best technology, but a businessready, complete production concept. Our heavy duty extrusion lines enable the production of several different products like tap water, gas, PE casing pipes, heating pipes, meaning the capacity can be adopted to where needed at the time.

Extrusion Lines by Pipe Manufacturer

KWH Pipe Technology provides complete extrusion lines for PE-HD pipe manufacturing in dimensions ranging from 16 up to 1600 mm. In addition, we also supply PP-r and PEX pipe manufacturing equipment.

Pipe Manufacturing
Cooling bath Haul-off Cutting unit

Raw material hopper

Electric motor

Extruder

Diehead with die Calibrator and mandrel Warm zone Cold zone

Partnership

Technolog

Efficient Raw Material Handling

Raw material handling system is designed to transfer raw materials to the feed hopper of the extruder and to keep the manufacturing process continuous. The system comprises the following components: Vacuum conveyor, which transfers raw material granulate from the storage bunker to the feed hopper of an extruder, or alternatively to an optional dryer. An optional raw material dryer completed with a vacuum conveyor, which transfers raw material granulate from the dryer to the feed hopper of the extruder. Tubes for transporting of raw material are of stainless steel. Air ducts of the raw material transfer system are of aluminum alloy.

RAW MATERIAL HANDLING SYSTEM

TYPE Type 1 500 Type 2 1000 Type 3 1500 Type 4 2000

Capacity kg / h

Real-Time Monitoring, Real-Time Value

Gravimetric control system (GCS) monitors the raw material consumption in real-time mode and compares it to the haul-off speed. If any deviation of actual metric weight from its calculated value occurs, GCS corrects the speed of the extruder or the speed of the haul-off unit. According to the Customers demand and requirements, the GCS instrumentation and software are delivered either for single-flow or multi-flow monitoring. A basic GCS is comprised of following 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)

Single Screw Extruders

The pipe extruder is designed for the manufacturing of polyolefin pipes. The product range comprises extruders 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 plastification rates and low melt temperatures Extruder barrel: Nitrated steel, HV 950 - 1000 Temperature control zones, heating/cooling Heating zones of extrusion die flange.

Diversified Extrusion Tools

The KWH pipe extrusion dies enable pipe extrusion of polyolefin materials, such as PE (HDPE, MDPE) and PP. The die-heads are of spiral distribution type. Dimensioning of the flow channels is based on the rheological characteristics of the most frequently used types of plastics. Optionally the die head can be equipped with Internal Cooling System for shorten cooling length or increasing output. The Advantages: low head volume enables short dwell times and low thermal stress impressed upon the melt low pressure build-up even at high material throughput 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.

Technolog

Save Energy, Produce More:

High output 37 L/D extruder series for the demands of energy saving and constant distribution. Standard water-cooled AC -motor: Excellent coefficient of efficiency (92,9 %). Low noise level <75 dB(A), without heat losses to the production hall. Energy saving water-cooled drive: The intelligent frequency converter adjusts magnetization according to the load, which means improved efficiency. Advanced barrel cooling: Cooling fins and ceramic heaters ensures accurate melt temperature. Internal cooling of the screw is optionally available. Constant output: Spiral grooved feed section creates circumstances for formation of even constant and homogenous high output of the melt flow.

High Performance 37 L/D Extruder

Closed loop cooling system: Extruders provided with closed cooling system have water-cooled motor, drive, control cabin, gear and barrel. Internal screw cooling as option. The system is silent with no heat losses to the environment. It is easy to connect to the factorys cooling system or process water. Due to glycol composition the closed system remains clean and rustless. Movable operator control panel and Internet remote connection: Mobile control panel can be moved either side of the 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 connection with customers accessible I.P. Address. Mixer (Option): The mixer ensures huge increase of output and homogenous melt with even distribution for different kind of master batches. The hemispherical cavities of the mixer force the raw material travelling along the barrel continuously changing direction, causing shearing and cutting action to the melt.

Technolog

Advanced Calibration Tools

Calibration gives the pipe its final shape and size. KWH provides complete range of calibration sleeves for vacuum and pressure calibration. Our long experience in pipe manufacturing allows precise designing of the sleeves that optimizes production. High quality calibration tools ensure round pipes with excellent surface and lower overweight of the pipe products. Pipe Calibration Tanks The calibration tank can be either of single or double chamber construction. The bottom part of the unit is used as a water reservoir, which ensures precise temperature control in the calibration tank. The temperature of the calibration tank is kept on the desired level by a thermostat. The calibration tank is installed on the rail tracks, anchored to the workshops floor. The longitudinal movement of the calibration tank is motorised. Haul-off unit The haul-off unit grips the pipe over a long length and pulls it at a constant speed. The haul-off consists of a number of pulling belts around the pipe. The pulling belts, which are located under the extrusion axis, are mechanically adjustable and upper ones are driven pneumatically. Pipe cutting equipment Pipes with a diameter over 160 mm are usually cut to the standard length. Circular saws Circular saws for cutting pipes of outer diameter up to 250 mm. Planetary saws The planetary saw is delivered as a single cut unit. By request any planetary saw can be equipped with twostep cutting heads. The initial cut is executed by disk saws and the final operation by cutting blades. In that way ingress of sawdust inside the pipe is prevented.

Vacuum Calibration Tanks

TYPE Pipe diameter , mm VCA 63-6 10 - 63 VCA 110-6 20 - 110 VCA 250-6 50 - 250 VCA 400-6 63 - 400 VCA 630-6 110 - 630 VCA 800-6 250 - 800 VCA 1200-6 630 - 1200

Spray Cooling Baths

TYPE Pipe diameter , mm SB 6310(6) 10 - 63 SB 11010(6) 20 - 110 SB 25010(6) 50 - 250 SB 40010(6) 63 - 400 SB 63010(6) 110 - 630 SB 80010(6) 250 - 800 SB 120010(6) 630-1200 SB-16006(4) 710-1600

Pressure Calibration Tanks

TYPE Pipe diameter , mm PCA 1200 400 - 1200 PCA 1600 710-1600

Haul-Off Units
TYPE Pipe diameter , mm PVL 110/3 16 - 110 PVL 250/4 50 - 250 PVL 400/6 40 - 400 PVL 630/6 110 - 630 PVL 800/6 140 - 800 PVL 1000/8 160 -1000 PVL 1200/10 315 - 1200 PVL 1600/12 710 - 1600

Technolog

Full Process Control

The control system constantly monitors the manufacturing process on its every stage and corrects current production parameters to the set value. Basic control system provides following services to the manufacturing process: Speed control of all installed drives of the production 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 flow control Alarm reporting and diagnostics. Integrating the gravimetric control into the basic control system enables enhanced process monitoring and run mode optimization, saving raw materials and other resources. Extended operation control system The operation control system of a single extrusion line can be connected to the PC-based upper level control system, which integrates and administers control systems of all installed production lines of the factory. This enables effective and comprehensive process control, including operation security and coordination. The extended operation control system allows the manufacturing process automation. Wall thickness ultrasonic measure control (UMC) The wall thickness ultrasonic measure control is to maintain the high and stable product quality and to minimize consumtion of specific raw materials. The core of the ultrasonic measure control system is the high-speed ultrasonic evaluation electronics and the sensor system. The processed data is displayed on the UMC output screen and used by the process control system to correct the performance of the extrusion line. The UMC controls the following operations and related parameters: metric weight (haul-off / extruder) minimum wall thickness (haul-off) wall thickness profile (die head centering) diameter (vacuum) extruder/start-up ramps component dosing co-extrusion.

10

Aftersales
KWH provides services by our skilled and professional staff. Our customer service offers original spare parts with flexible and short delivery times. Customers staff is trained in Finland and during the start up at the customers premises. Our experienced technicians assists and helps you to maintain best quality products in your manufacturing line. We invest time in understanding the customer and provide top-class service from start to finish. Our customers success is our success

11

Professional Solutions for Plastics Industry

KWH Pipe Technology designs and manufactures machinery and provides advanced technology for the plastics industry. KWH Pipe Technology is a part of the KWH Pipe Group, a world leader in manufacturing and development of plastic pipe systems having production plants in Europe, North America and South Asia. Since the 1960s, the Technology department of KWH Pipe has been supplying equipment and technology solutions for customers worldwide. KWH Pipe Technology offers a wide range of high quality products and services and carries out complete turnkey factory projects.

KWH Pipe Ltd, Technology P.O. Box 383 FI-65101 Vaasa, Finland (Head office) Tel. + 358 6 326 5511 Telefax +358 6 326 5690 E-mail: [email protected] www.kwhtech.com