High Speed High Efficient PE Pipe Extrusion Line

Short Description

Description

Hdpe pipe machine is mainly used for producing agricultural irrigation pipes, drainage pipes, gas pipes, water supplying pipes, cable conduit pipes etc.
PE pipe extrusion line consists of pipe extruder, pipe dies, calibration units, cooling tank, haul-off, cutter, stacker/coiler and all peripherals. Hdpe pipe making machine produces pipes with the diameter from 20 to 1600mm.
The pipe has some excellent features such as heating resistant, aging resistant, high mechanical strength, environmental stress cracks resistant, good creep resistant, etc. Hdpe pipe extrusion machine is designed with high efficiency extruder and equipped with reducer which is high speed and low noise, gravimetric dosing unit and ultrasonic thickness indicator can be assembled according to customer’s demand to ascend the precise of the pipes.
Turn key solution can be provided, like laser printer crusher, shredder, water chiller, air compressor etc. to achieve high-grade and automatic tube production.

Process Flow

Raw material+ Master Batches → Mixing → Vacuum Feeder →Plastic Hopper Drier→ Single screw extruder →Co-extruder for color string & Multi Layers → Mould and calibrator→ Vacuum Calibration Tank → Spray Cooling Water Tank → Haul-off machine → cutting machine→ Stacker(Winding machine)

Features and Advantages

Hdpe pipe machine is developed by us based on European advanced technology and R&D experience of plastic machinery for many years, advanced design, reasonable structure, high reliability, high degree automation.
2. Hdpe pipe extruder with special barrel feeding structure can largely improve extrusion capacity.
3. Accurate temperate control, good plasticization, stable operation.
4. Hdpe pipe machine adopts PLC control system, realizing synchronization and automation.
5. Human-computer interface is easy to operate, convenient and reliable.
6. Spiral and lattice basket type die dead for choice.
7. Changing some parts of the line can also realize two-layer and multi-layer co-extrusion.
8. Changing some parts of the line can also produce PP, PPR pipes.

Details

Single Screw Extruder

Based on 33:1 L/D ratio for screw design, we have developed 38:1 L/D ratio. Compared with 33:1 ratio, 38:1 ratio has advantage of 100% plasticization, increase output capacity by 30%, reduce power consumption up to 30% and reach almost linear extrusion performance.

Simens Touch Screen and PLC
Apply program developed by our company, have English or other languages to be input into the system.
Spiral Structure of Barrel
Feeding part of barrel use spiral structure, to ensure material feed in stable and also increase feeding capacity.
Special Design of Screw
Screw is designed with special structure, to ensure good plasticization and mixing. Unmelted material can not pass this part of screw.
Air Cooled Ceramic Heater
Ceramic heater ensure long working life. This design is to increase the area which heater contact with air. To have better air cooling effect.
High Quality Gearbox
Gear accuracy to be ensured 5-6 grade and lower noise below 75dB. Compact structure but with high torque.

Extrusion Die Head

Extrusion die head apply spiral structure, each material flow channel is placed evenly. Each channel is after heat treatment and mirror polishing to ensure material flow smoothly. Die head structure is compact and also provide stable pressure, always from 19 to 20Mpa. Under this pressure, pipe quality is good and very little effect on the output capacity. Can produce single layer or multi-layer pipe.

Moving Device of Die Head
For big size die head, moving device can move die head forward and back, also adjust the height of die head. Operation is fast and easy.
Die Head Rotary Device
For big size die head with rotary device, die head can rotate by 90 degree. When changing bush, mandrel, die head will turn 90 degree. Can use crane to lift and change bush and mandrel. This way is very convenient.
Heat Exhausting Device
This device is added on die head to produce big and thick pipe. To exhaust heat inside the pipe and cooling pipe inside wall. The heated exhausted can be used to dry the raw material.
Cooling Device for Core
When produce pipe with big diameter and wall thickness, we will use cooling water or oil together with cooling fan to cool the core of die head to avoid over heating and ensure good material quality.

Vacuum Calibration Tank

Vacuum Calibration tank is used to shape and cool pipe, so as to reach standard pipe size. We use double-chamber structure. First chamber is in short length, to ensure very strong cooling and vacuum function. As calibrator is placed in the front of first chamber and pipe shape is formed mainly by calibrator, this design can ensure quick and better forming and cooling of pipe.

Strong Cooling for Calibrator
With special cooling system for calibrator, which can have better cooling effect for pipe and ensure high speed. Also with good quality spray nozzle to have better cooling effect and not easy blocked by impurities.
Better Support for Pipe
For big size pipe, each size has its own semicircular support plate. This structure can keep pipe roundness very well.
Silencer
We place silencer on the vacuum adjust valve to minimize noise when air come into the vacuum tank.
Pressure Relief Valve
To protect the vacuum tank. When vacuum degree reach maximum limitation, the valve will open automatically to decrease vacuum degree to avoid broken of tank. Vacuum degree limitation can be adjusted.
Double Loop Pipeline
Each loop with water filtering system, to provide clean cooling water inside tank. Double loop also ensure continuous providing of cooling water inside tank.
Water, Gas Separator
To separate the gas water water. Gas exhausted from upside. Water flow into the downside.
Full Automatic Water Control
With mechanical temperature control to have accurate and stable control of water temperature.
Whole water inlet and outlet system is controlled full automatic, stable and reliable.
Centralized Drainage Device
All water drainage from vacuum tank are integrated and connected into one stainless pipeline. Only connect the integrated pipeline to outside drainage, to make operation easier and faster.

Spray Cooling Water Tank

Cooling tank is used to cool pipe further.

Pipe Clamping Device
This device can adjust pipe roundness when pipe comes out from the vacuum tank.
Water Tank Filter
With filter in the water tank, to avoid any big impurities when outside water comes in.
Quality Spray Nozzle
Quality spray nozzles have better cooling effect and not easy blocked by impurities.
Pipe Support Adjusting Device
Support with adjustment function to support pipe with different diameters.
Pipe Support Device
Especially used when producing pipe with big diameter and wall thickness. This device will provide additional support to heavy pipes.

Haul Off machine

Haul off machine provides sufficient traction force to pull pipe stably. According to different pipe sizes and thickness, our company will customize traction speed, number of claws, effective traction length. To ensure match pipe extrusion speed and forming speed, also avoid deformation of pipe during traction.

Separate Traction Motor
Each claw has its own traction motor, in case when one traction motor stop working, other motors can still working. Can choose servo motor to have bigger traction force, more stable traction speed and wider range of traction speed.
Claw Adjustment Device
All claws are connected to each other, when adjusting position of claws to pull pipe in different sizes, all claws will move together. This will make operation faster and easier.
User Friendly Design
With Siemens hard ware and user friendly software designed by our company. Have synchronized function with extruder, make operation easier and faster. Also customer can choose only some of claws to work to pull much smaller pipes.
Separate Air Pressure Control
Each claw with it own air pressure control, more accurate, operation is easier.

. High pulling force without lose the shape of the pipes
. Equipped with 2, 3, 4, 6, 8,10 or 12 caterpillars according to the application
. Servo motor driving for providing stable torque and running
. Motorized positioning of the lower caterpillars
. Simple operation
. Completely closed protection for maximum safety
. Chain conveyors with special rubber pads on chains which do no mark on the pipe.
. Synchronization with the extruder screw speed allows stable production during changing the production speed

Pipe cutting machine

Plastic pipe cutter also called pipe cutting machine controlled by Siemens PLC, working together with haul off unit to have precise cutting. Customer can set the length of pipe they want to cut. Multi-feed-in actions for the accomplishment of one cutting process (protect blades and saws, prevent from blade and saws stuck for thick pipe and cut face of pipe is smooth).

Universal Clamping Device
Apply universal clamping device for different pipe sizes, no need to change clamping device when pipe size changes.
Saw and Blade Interchangeable
Some cutters are equipped with both saw and blade. Saw and blade cutting are interchangeable for different pipe sizes. Also, saw and blade can work together for special requirement.
Central Height Adjustment
With electrical adjusting device for clamping device. Operation faster and easier. With limit switch to ensure safety.

. Automatic synchronization with extrusion speed
. Planetary equipped with disk and milling cutter for cut and chamfering
. Chip-free equipped with disk blade to ensure smooth cutting surface without any dust
. Touch screen control panel
. All movements are motorized and controlled by control panel
. Pipe blocking with using universal clamping for easy operation
. Less maintenance needs
. Completely closed and secured machine for maximum safety

Stacker

To support and unload pipes. Length of stacker can be customized.

Pipe surface protection
With roller, to protect pipe surface when moving pipe.
Central Height Adjustment
With simple adjustment device to adjust the central height for different pipe sizes.

Coiler

To coil pipe into roller, easy for storage and transportation. Usually used for pipe below size 110mm. Have single station and double station for choice.

Use of servo motor
Can choose servo motor for pipe displacement and winding, more accurate and better pipe displacement.

Technical Data

Diameter range(mm)	Extruder model	Max. Capacity(kg/h)	Max. lineal speed(m/min)	Extruder power (KW)
Ф20-63	SJ65/33	220	12	55
Ф20-63	SJ60/38	460	30	110
Ф20-63 Dual	SJ60/38	460	15×2	110
Ф20-110	SJ65/33	220	12	55
Ф20-110	SJ60/38	460	30	110
Ф50-160	SJ60/38	460	15	110
Ф75-250	SJ75/38	600	12	160
Ф200-450	SJ90/38	850	8	250
Ф315-630	SJ90/38	1,050	4	280
Ф500-800	SJ120/38	1,300	2	315
Ф710-1200	SJ120/38	1,450	1	355
Ф1000-1600	SJ 90/38 SJ 90/38	1,900	0.6	280 280