PE Pipe Extrusion Process (4)

Die Design

The pipe extrusion die supports and distributes the homogeneous polymer melt around a solid mandrel, which forms it into an annular shape for solid wall pipe . The production of a profile wall pipe involves extruding the molten polymer through a die which has a certain shaped profile.

The die head is mounted directly behind and downstream of the screen changer unless the extruder splits and serves two offset dies.

There are two common types of die designs for solid wall pipe; the spider die design and the basket die design. They are illustrated in Figure 5. These designs refer to the manner in which the melt is broken and distributed into an annular shape and also the means by which the mandrel is supported.

In the spider die (Figure 5.1), the melt stream is distributed around the mandrel by a cone which is supported by a ring of spokes. Since the melt has been split by the spider legs, the flow must be rejoined.

Flow lines caused by mandrel supports should be avoided. This is done by reducing the annular area of the flow channel just after the spider legs to cause a buildup in die pressure and force the melt streams to converge, minimizing weld or spider lines. After the melt is rejoined, the melt moves into the last section of the die, called the land.

The land is the part of the die that has a constant cross-sectional area. It reestablishes a uniform flow and allows the final shaping of the melt and also allows the resin a certain amount of relaxation time. The land can adversely affect the surface finish of the pipe if it is too short in length. Typical land lengths are 15 to 20 times the annular spacing.

The basket design (Figure 5.2) has an advantage over the spider die concerning melt convergence. The molten polymer is forced through a perforated sleeve or plate, which contains hundreds of small holes. Polymer is then rejoined under pressure as a round profile. The perforated sleeve, which is also called a screen basket,eliminates spider leg lines.

PE Pipe Extrusion Process (1)

Pipe Extrusion

The essential aspects of a solid wall PE pipe manufacturing facility are presented in Figure 1. This section will describe the production of solid wall pipe from raw material handling, extrusion, sizing, cooling, printing, and cutting, through finished product handling. Details concerning profile wall pipe are also discussed in the appropriate sections.

Raw Materials Description

The quality of the starting resin material is closely monitored at the resin manufacturing site. As discussed in the chapter on test methods and codes in this handbook, a battery of tests is used to ensure that the resin is of prime quality. A certification sheet is sent to the pipe and fitting manufacturer documenting important physical properties such as melt index, density, ESCR (environmental stress crack resistance), SCG (slow crack growth), stabilizer tests, amongst others.The resin supplier and pipe manufacturer may agree upon additional tests to be conducted.

Extrusion Line

The raw material, usually referred to as PE compound, is typically supplied to the pipe producer as non-pigmented pellets. PE pellets are stabilized for both heat and UV protection. Usually, color pigment is added to the pipe at the producer’s facility. In North America, the most common colors are black and yellow. The choice of color will depend upon the intended application and the requirements of the pipe purchaser. Carbon black is the most common pigment used for water, industrial, sewer and above-ground uses. Yellow is reserved exclusively for natural gas applications, although black with yellow stripes is also permitted for this application. Other colors are used for telecommunications and other specialty markets. All ASTM and many other industry standards specify that a PPI-listed compound shall be used to produce pipe and fittings for pressure pipe applications. A compound is defined as the blend of natural resin and color concentrate and the ingredients that make up each of those two materials. The pipe producer may not change any of the ingredients. In a listed compound, such as substituting a different color concentrate that could affect the long-term strength performance of the pipe. Any change to a listed formulation has to be pre-approved. These stringent requirements ensure that only previously tested and approved compounds are being used.

If the resin is supplied as a natural pellet, the pipe producer will blend a color concentrate with the resin prior to extrusion. In order to obtain a PPI Listing, each manufacturer producing pipe in this manner is required to submit data, according to ASTM 2837, to the PPI Hydrostatic Stress Board. A careful review of the data is made according to PPI Policy TR-3 (5) to assess the long-term strength characteristics of the in-plant blended compound. When those requirements are met, the compound qualifies for a Dependent listing and is listed as such in the PPI Publication TR-4 (6), which lists compounds that have satisfied the requirements of TR-3. Producers of potable water pipe are usually required to have the approval of the NSF International or an equivalent laboratory. NSF conducts un-announced visits during which time they verify that the correct compounds are being used to produce pipe that bears their seal.

Raw Materials Handling

After the material passes the resin manufacturer’s quality control tests, it is shipped to the pipe manufacturer’s facility in 180,000- to 200,000-pound capacity railcars, 40,000-pound bulk trucks, or 1000- to 1400-pound boxes. Each pipe producing plant establishes quality control procedures for testing incoming resin against specification requirements. The parameters that are typically tested include: melt flow rate, density, moisture content and checks for contamination. Many resin producers utilize statistical process control (SPC) on certain key physical properties to ensure consistency of the product. Resin is pneumatically conveyed from the bulk transporters to silos at the plant site. The resin is then transferred from the silos to the pipe extruder by a vacuum transfer system. Pre-colored materials can be moved directly into the hopper above the extruder. If a natural material is used, it must first be mixed homogeneously with a color concentrate. The resin may be mixed with the color concentrate in a central blender remote from the extruder or with an individual blender mounted above the extruder hopper. The blender’s efficiency is monitored on a regular basis to ensure that the correct amount of color concentrate is added to the raw material.

Advantages of Single Screw Extruder

     Advantages of Single Screw Extruder

The significant advantages the Single Screw Extruder with barrier according to the present invention has the advantage that the pressure build-up capability is improved. Compared to the known Twin Screw Extruder it is not necessary any more to build up a very high pressure in the so-called feed zone as to enable a predetermined lower pressure at the end of thegravimetric feeder With the according to the present invention it is possible to substantially reduce the pressure between the feed zone and the melting zone. This in turn results in a reduction of wear of the gear pump in the transition area between the feed zone and the melting zone since it is operated with lower pressures.

(1)In a preferred embodiment the barrel comprises several grooves being equally spaced apart in circumferential direction which grooves extend preferably parallel to the longitudinal axis of the barrel. This has the advantage that the process of matching the grooves is simplified compared with the groove helically arranged.

(2)Due to the pressure reduction in the area of the feed zone it does not have to be constructed any more as complicated as in prior solutions and does not have to be provided with cooling means and a “heat separation” towards the heated melting zone. Advantageously, the feed zone and the melting zone may therefore be formed individually.

(3)In a further preferred embodiment the width and/or the depth of the groove varies in a longitudinal direction, preferably the grooves depth decreases towards the downstream end of the melting zone section, preferably to zero.

This has the advantage sheet production extruderthat the groove extends continuously without Single Screw Extruderany break along the feed zone and melting zone thereby further improving the output and the pressure build-up. 

In a further preferred embodiment of the invention at least one groove is provided also in the barrel inner surface (innerwall) in the area of the feed zone section, the groove extending parallel or helically relative to the longitudinal axis. Preferably, the groove in the area of the feed zone section leads into the groove in the area of the melting zone without transition. Preferably both grooves have the same lead angle.

What are the key differences between PVC and PE pipes and fittings?

      What are differences between PVC and PE pipes ?

PE  benefits

• Chemically inert, no off gassing or leaching.
• Flexible, can be pulled to around corners to eliminate fittings.  This give a better water flow, and saves time and money.
• Can freeze without bursting
• Is rated to last at least 200 years
• No glue to add poisonous vapors or soldering to reduce risk of fire.

Negatives

• Pipe and fittings are reduced in diameter, may need to up size for good flow.
• Pipe has no rigidity.  Must be supported it's entire length.
• Need special tools to install.

PVC and CPVC "for hot" benefits

• Any can do it, all you need is a cutter to assemble.
• Very cheap and you can get it anywhere.
• PVC is full bore, but only for cold water.

Negatives

• All sorts of leaching flavors and chemicals into water.
• Rated for 20 years, this is an over statement.
• Glue needs to cure for 24 hours before charging with pressure.  Most do not do this, but that is what is instructed.
• Freezes and bursts quite quickly.
• Some plumbers will not attach to it for it has a high failure rate.

How to Make Plastic Pipes

             How to Make Plastic Pipes

Plastic has largely become the material of choice for pipes. Its flexibility, ease of bonding, lighter weight than iron and steel and lower cost than copper has made it a common choice. Pipe is generally produced by an extrusion process. Although this process may vary in actual operating conditions (temperatures, pressures, extrusion rate) based on the type of plastic used, diameter of pipe and wall thickness, the fundamental process of extrusion is reasonably consistent throughout the industry. 

• Add the thermoplastic resin to the feed hopper. Although this can be done manually, it is generally transferred to the hopper via a vacuum feeder due to the steady state nature of the process. This helps minimize the chance of running out of resin during the process.
• Turn on machine screw and barrel heaters per specific resin requirements. The heaters add heat to the plastic while it is in the barrel to melt the plastic. The rotating screw adds shear heat to the plastic for melting as well as building up the pressure to force the plastic through the die.
• Extrude plastic through the die. The die is designed and built based on the dimensions desired in the pipe and the shrink rate of the type of plastic being used.

• Cut the pipe at the desired length. The extruded pipe will exit the die onto a roller system to allow the pipe to cool without deforming under its own weight. Once it has passed a certain length, it will trip a sensor (electric eye) triggering a cutting operation on the pipe. The cut is made by a cutter that moves forward at the rate of pipe extrusion to offset the motion of the pipe moving forward so that the end of the pipe will remain perpendicular to the pipe wall after it is cut.
• Continue the process in a steady-state environment until the desired quantity of plastic is produced.

           The Plastic Manufacturing Process

Plastic Extrusion Molding Process

• Extrusion molding is another method of manufacturing plastic components. Extrusion molding is very similar to injection molding and is used to make pipes, tubes, straws, hoses and other hollow pieces. Plastic resin is fed into a barrel where it is liquefied. A rotating screw propels the liquefied plastic into a mold, which contains a tube-shaped orifice. The size and shape of the tube determines the size and shape of the plastic piece. The liquefied plastic then cools and is fed through an extruder, which flattens the plastic and forms the piece into its final shape.

Plastic Injection Molding Process

• Injection molding is one of the main methods by which parts are manufactured from plastic. The first step in the injection molding process is to feed plastic pellets into the hopper, which then feeds the pellets into the barrel. The barrel is heated and contains a reciprocating screw or a ram injector. A reciprocating screw is typically found in machines that produce smaller parts. The reciprocating screw crushes the pellets, making it easier for the plastic to be liquefied. Toward the front of the barrel, the reciprocating screw propels the liquefied plastic forward, thereby injecting the plastic through a nozzle and into the empty mold. Unlike the barrel, the mold is kept cool to harden the plastic into the correct shape. The mold plates are held closed by a large plate (referred to as a movable platen). The movable platen is attached to a hydraulic piston, which puts pressure on the mold. Clamping the mold shut prevents plastic from leaking out, which would create deformities in the finished pieces. 

Extrusion System For Plastics Extrusion Machine

Extrusion system consists of screw and barrel, Hopper, die, and die, plastics by squeezing the system plastics melt evenly, and, in the process of establishing, under pressure from continuous by screw extruder.

1, screw: is the most important parts of extruder, it is directly related to applications and productivity of extruders, made from high-strength corrosion-resistant alloy steel.

2, barrel: is a metal cylinder, generally with higher heat resistance, compressive strength, strong wear-resistant, corrosion-resistant alloy steel composite pipe made of or lined with alloy steel. Barrel and screw fit, realize the plastic pieces, softening, melting and plasticizing, vent and compaction, and uniform conveyor rubber molding system. Barrel length is 15~30 times the diameter, so that the plastic is fully heated and fully plastic into principles.

3, Hopper: hopper with cut-off device at the bottom, so you can adjust and cut off the flow, side of the hopper with sight and calibration of metering devices.

4, die and mold: head made of alloy steel and carbon steel coat, and head is equipped with mold, heads are used to rotate the plastic melts into parallel straight line movement, steady import model Kit, and endows plastics with the necessary pressure. Plastic plastic in the barrel of the compaction, porous plate along a certain flow through head neck into head mold, die mandrel set appropriate, formation cross section decreases of the annular space, plastic melt around the wire to form a continuous solid tube coating. In the guarantees head plastic reasonable channel, elimination of accumulated plastic corner, often placed with split sleeves, for elimination of plastic extrusion pressure fluctuations, there is set of grading rings. Head is also equipped with mould correction and adjustment device, easy to adjust and align core and mould sleeve of concentricity.