Pipe and profile machinery
CPVC pipes go mainstream The chlorinated polyvinylchloride (CPVC) pipes market in India is growing at a healthy rate due to tremendous government spending on infrastructure. This has led Rajoo-Bausano, a pipe machinery joint venture set up in India, to cater to the demand with new machinery. Indian extrusion machinery maker Rajoo Engineers entered into an equal equity joint venture with Italy-based pipe machinery maker Bausano in 2010 to manufacture and market pipe/profile extrusion lines in India with special emphasis on the African, Gulf and SAARC markets.
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he boom in the building and construction industry, especially in the housing and commercial building sector, has fuelled high demand for cost effective, reliable and quality piping and plumbing systems. It is estimated that there are more than 20 CPVC pipe manufacturers in India while the growth rate of this sector is approximately 40% a year. According to Sunil Jain, Director of RajooBausano, “CPVC pipes are a logical and cost-effective choice over copper, galvanised, iron and alternative Sandip Bhuva says that plastic systems. These pipes are safer, faster and easier to install, hence saving on labour costs.” Sunil the new joint venture offers the Indian market adds that CPVC has a number of features that make it competitive machinery an improvement over conventional piping systems. “It is readily workable, including machining, welding and forming, and has excellent corrosion resistance at elevated temperatures. CPVC is also non-toxic, while PVC may leech toxins into water at increased temperatures,” he adds. More specifically, cold welding using CPVC solvent is fast and simple, ensuring leak-free installation for the entire life span of the piping system, said Sunil. “CPVC piping is recognised in all model plumbing codes. For hot and cold water applications,CPVC pipes and fittings are pressure rated as per ASTM D 2846 for continuous use at 100 psi at 180°F and 400 psi at room temperature. CPVC is fire resistant and will not burn without a flame source, making it suitable for fire suppression systems in light hazard and residential settings.”
New launch of machinery With the urbanisation rate and growth in infrastructure spending in India, Sunil reckons that the trend in the country will change to the use of newer piping material and hence, the introduction of new machinery for this. To date, Rajoo-Bausano has launched machines for rigid polyvinylchloride (RPVC), CPVC and polyethylene (PE) pipes. Twin-screw pipe plants are available with outputs range from 200 kg/hour to 2,000 kg/hour and pipe diameters range from 15 mm to 1,000 mm. Rajoo-Bausano says it offers the widest range of high productivity and energy efficient twin-screw extruders TwinEx with the “Multidrive” system for the production of RPVC/UPVC pipes, CPVC pipes, profiles, granulations and medical tubes, complete with downstream equipment. Speaking about the machinery’s highlights, Sandip Bhuva, General Manager of the joint venture, said, “Due to the machine’s higher L/D ratios, the extruders enhance melt homogenisation at higher output levels, compared to competitor models with similar size extruder and motor ratings. This results in lower energy costs, which is the second biggest cost component after raw materials. Furthermore, the machines help in easy processing of a wide range of formulations.” The line also incorporates a revolutionary transmission system known as “Multidrive”. Said Sandip, “It has great advantages in terms of the durability and performance of the extruder. Some of the advantages include elimination of the torsional stress on the driving shaft and multi-stage thrust bearings that give a threefold increase in the dynamic load to absorb the increased load at high production levels without any problems.”
Pipe and profile machinery Temperature in the screw is controlled by internal circulation of silicone oil and a thermocontrol unit for better processability. High efficiency air cooling for the barrel zone and an oil cooling system for higher output lines are other salient features. Other features include the online power measuring system, special coating on the screw, automatic diameter and thickness control system and an online belling system. Competitively priced machinery To maintain competitive pricing, the machinery from Rajoo-Bausano will be made in India. “Initially the screw, barrel and patented gearbox will be supplied by Bausano from Italy but within two years these will be manufactured in India. All other assemblies are made in India in accordance with Bausano’s technology,” said Sandip. He also pointed out the attractive price/performance ratio compared to Western machinery as the line combines “Rajoo’s best-in-the-class
infrastructure and Bausano’s sublime pioneering technology.” Another highlight of the Rajoo-Bausano pipe machinery is that it incorporates the vacuum sizing technique while many competitors still use the obsolete bung sizing, said Sandip. “Vacuum sizing enhances product quality in terms of product surface smoothness and dimensional accuracy. Higher line speed can be achieved through the unique design of such a calibrator. The tanks are made of stainless steel for high corrosion resistance and long useful life. The three axis adjustment system with motorised lateral position control allows for quick precise positioning. The final benefits are reduced energy consumption while transporting fluids through the pipe in addition to controlled weight per meter of the pipe,” emphasises Sandip. When asked if any machines had been sold yet, Sandip said, “We are in discussions with many prospects and close to finalising the deals.”
Rajoo-Bausano’s CPVC pipe line
The joint venture does not intend to rest on its laurels just yet, having launched a wide portfolio. It will be launching machinery for profiles for unplasticised polyvinylchloride (UPVC) and wood plastic composites (WPCs), which will be available by next year. The company will also be introducing granulators for rigid and flexible PVC, polyolefins, TPR and masterbatch, shortly, said Sandip. “We will be launching more machines from the Bausano portfolio soon. Customers will now have world class technological products at affordable price levels,” he concluded.
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ccompanying the growth of China’s plastics industry for over 12 years, China Plastics Exhibition & Conference (China PEC) has become a distinguished meeting and business platform for the plastics industry and has also largely contributed to it’s prosperous development. At present, China PEC is the only exhibition in the plastics industry supported by the Ministry of Commerce of China and it is also widely recognised by the industry as one of the most influential exhibitions in China. China PEC is a showcase for all the elements of the industry, such as plastic products, raw materials, machines, moulds and dies as well as related technologies. To be held from 22-25 September at the Taizhou International Convention & Exhibition Centre, Zhejiang, China PEC 2012 will have 1,600 booths with a total exhibition area of 35,000 sq m. Zhejiang province, being the biggest plastic manufacturing base in China, is location-strategic for both the local and foreign visitors and exhibitors to conveniently approach the Chinese local markets.
Strong plastic industrial base In Taizhou, there are more than 11,000 enterprises specialising in the plastic industry, and their annual sales reach RMB46.5 billion (About US$7 billion). In 2008, the plastic consumption in Taizhou was more than 4 million tonnes, which accounts for nearly 10% of total consumption in China. A kingdom for plastic products 3 Taizhou is the largest production base for plastic products in China offering the widest array of items at the lowest prices. 3 Taizhou is also the largest plastic products distributing centre in China. 3 Taizhou is home to more than 2,000 mould manufacturers. Total output value produced by these manufacturers in 2008 reached RMB8.75 billion (about US$1.5 billion). The price of plastic moulds manufactured in Taizhou is 10% lower than the prices of moulds made in other countries.
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AUGUST 2012
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Pipe and profile machinery
Extrusion machinery expands applications The world plastic pipe market is forecast to reach 7.6 billion m by 2017, according to Global Industry Analysts. Heavy infrastructure investments and the rise in construction activity in emerging markets will be the driving force behind advances in the global market. Meanwhile, extrusion equipment will post the strongest gains in the growth of processing machinery, due to the demand for pipes for the automotive and infrastructure sectors and profiles in the building industry.
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Machinery makers cashing in on growth Besides the Indian market (see story on Rajoo-Bausano), China is also witnessing growth in CPVC processing, according to machine maker KraussMaffei Berstorff. It has sold several machines to Youli Holding Group, one of the largest CPVC producers in China, over the last ten years. The most recent order included a KMD 130-26 twin-screw extruder to produce pipes up to 800 mm and sheets, a new product line for Youli, says the firm. The extruder is able to switch production and has an output of 700 kg/hour for pipe production and 600 kg/hour for sheet production. The German firm has also sold several machines to Shanghai Chemical and Hangzhou Chemical, from its local production facility in Haiyan adding that it has recorded substantial orders for its twin-screw series for PVC and PO pipe and profile extrusion. The Chinaust Group, a leading pipe manufacturer in China, also ordered a complete pipe line to produce PE pipes up to a diameter of 400 mm at the start of this year while Zibo Jielin Plastic Pipe has taken delivery of a pipe machine for processing PBT from Lyondellbasell. KraussMaffei Berstorff has also recently introduced a complete system for producing TPV profiles for the automotive industry, applied by US-headquartered ExxonMobil Chemical in its Shanghai development centre for demonstration purposes. Another company that is seizing the opportunity in automotive growth is Italian machine maker Amut with its machinery for producing POM and PVDF pipes, with a diameter of 2.5 mm and thickness of 0.35 mm. These materials are particularly suitable for applications in the automotive sector due to the properties of stiffness, strength and dimensional stability, combined Amut’s latest machine caters to the production of small with low friction coefficient, giving the small hoses for the automotive pipes improved flow behaviour and wear/ industry chemical resistance. The latest line created by Amut for the European market is composed of its EA48 single-screw extruder, gear pump, calibration and cooling tanks with the possibility of temperature control, diameter/thickness gauging and adjusting system, haul-off, cutting unit and winder. At the end of the line an option is offered to cut the product in different lengths using a high-speed cutter, aided by an automated conveyor belt. Likewise, German firm Troester has developed a new technology for automatic wall thickness centering for hose production that comprises an optimised cross head, including a conventional manual die adjusted by screws in the front area that additionally allows for sensitive swivelling of the inner tools (mandrel tip, extrusion mandrel) by means of a hydraulic drive.
Pipe and profile machinery Contrary to conventional solutions where considerable force has to be applied hydraulically on to the outer die, the new design allows the mandrel tip to be positioned radially. As the hydraulic drive is positioned on the rear side of the head, away from the compound processing, a safe mechanical functioning of the adjustment unit is ensured, says the firm. US firm Milacron has expanded its TP parallel twin-screw extruders to include the TP75, a machine with a smaller, 75 mm screw diameter for the PVC pipe market. While previously small pipe/profile applications would have required a conical twin-screw, this production can be undertaken on the TP75, which includes five models for outputs of up to 2,267 kg/hour. Features include air and oil-cooled barrels, with optional gearbox oil quality monitoring and a tungsten screw/barrel. A longer 33:1 L/D option is also available Extruder for pipes and profiles After the twinEX twin-screw and the solEX single-screw extruder series for high-speed applications, come the uniEX single-screw extruders from Austrian firm Battenfeld-Cincinnati. Suitable for manufacturing both pipes and profiles, the series is available in four sizes for outputs from 50-500 kg/hour. A highlight is what the machine maker says is high specific output at every screw speed, due to the extruder’s feed zone. An additional benefit is the wide process window as well as the option of processing
Battenfeld-Cincinnati’s multi-purpose extruder for both pipes and profiles
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a variety of materials thanks to specialised screw geometries. The extruder also favours high output at low melt temperatures. The processing units are mounted on a robust basic frame in a space-saving U configuration. The powerful drive system allows for melt pressures of up to 500 bar while maintenance-free AC motors keep energy consumption low. Other highlights are the uniform control cabinets and control units used for the first time in this series, allowing for easy operation and for the option of having several extruders of a co-extrusion line integrated in a single control system if desired. Machinery for flexible, umbilical pipes Today’s oil exploration is reaching into remote locations and harsh environments. One clear example was brought to the public’s attention in the fairly recent Gulf of Mexico catastrophe. Ultra deepwater wells are connected to platforms and production units via a network of flexible and umbilical pipes. Maillefer’s PFL extrusion systems are well suited for the production of flexible or umbilical and carcass pipes
The complex pipe constructions vary widely to include several functional layers, metallic reinforcements, builtin tubes and pipes, wires, cables or fibre optics. Flexible pipes serve to transport the crude oil and gas, while umbilical pipes are used to drive the deepwater well with power, hydraulics, control signals and communications, all circulating in the same package. Swiss firm Maillefer says its PFL extrusion systems are well suited for the production of flexible or umbilical pipes. Layers are applied through one or more extrusion passes. Standard line configurations include single or multiple layers; diameter of 50-630 mm; processing
of compounds like HDPE, PA, PVDF, PEX-b or TPE; and high flow extrusion with dimensional control. The system features easier forming tool set-ups, elimination of wear and dust from TIG grounding and improved weld surveillance. Foam fibre composite for profiles Italian firm Friul Filiere has developed a new technology for the extrusion of a new material known as Foam Fibre Composite (FFC), made up of 50% thermoplastics and 50% natural fibres. Formulated with stabilisers, lubricants and foaming agents, the homogeneous compound is ready for extrusion directly from dry-blend on extruding lines equipped with special singlescrew extruders or counter rotating twin-screw extruders. FFC can be used in the building sector, as a substitute for WPC, MDF or other thermoplastics. Similar to wood, FFC can be used for profile extrusion of windows, doors, skirting, fences and wall panels. The firm says it has received enquiries from the Southeast Asian market, especially Indonesia. At the PlastMilan exhibition in May, the firm had a live demonstration of FFC skirting profile extrusion and it has extended this to the production of decking profiles. The extrusion line for the latter consists of two Omega extruders and the Downstream Omega Evolution: the main extruder is a R63 conical twin-screw extruder, equipped with special screws and a cylinder. The co-extruder is an Omega S 60-25D single-screw which processes from granule, allowing for plasticisation of rigid PVC. The firm says its patented Downstream Omega Evolution also boasts energy savings of up to 40%.
Friul Filiere’s decking profile made from FFC and a rigid external film