September/October 2012
PE100 DELIVERS EXTENDED PERFORMANCE
LATEST IN TRENCHLESS TECHNOLOGIES
CO-EXTRUSION OFFERS MATERIAL SAVINGS
TOOLING UP WITH DOWNSTREAM EQUIPMENT
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contents
PAGE 5
05 Industry news
Onex buys KraussMaffei; Pexco begins new Odyssey; Sekisui seeks pipe leadership
in Japan; Arkema sells tin stabilisers; VDMA says machine sales will fall this year
11 Layered approach
PAGE 11
Co-extrusion is big business in pipe and profile extrusion, and is something that
suppliers are all clamouring to supply
19 Handle with care
Once your product is out of the die, there is plenty more handling to be done – all
PAGE 19
the way along the line. Lou Reade reports
27 Hundred club
PE100 leads the way for demanding high pressure piping – sometimes in the
remotest of locations. Lou Reade reports
33 Making the cut
PAGE 27
The new generation of trenchless technologies reduces installation costs for
plastic piping
37 Technology: Materials
PAGE 37
38 Technology: Machinery
40 Extruder of the month: Custom Profile
42 Dates for your diary
coming next issue
❙ PEX ❙ Materials handling equipment ❙ Wood-plastic composites ❙ PVC stabilisers
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www.pipeandprofile.com
September/October 2012 | PIPE & PROFILE EXTRUSION
3
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• Energy consumption of cooling section can
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• Cooling water consumption per hour can be
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• “Free Cooling“ can be increased by up to
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news
HallStar
buys Dow
plasticisers
Onex Corporation buys
KraussMaffei for E568m
HallStar has acquired the
German machinery manufac-
reputation for technology and
TP-series product line of
turer KraussMaffei is to get a
quality”, said David Mansell,
the extrusion market for Onex,
speciality plasticisers from
new owner.
an Onex managing director.
which acquired US-based
“We look forward to working
machinery company Davis-
Dow Chemical.
Canadian private equity
This is the second foray into
firm Onex Corporation will
with the management team to
Standard at the start of this
both the trade names and
acquire the company from its
further build on the company’s
year.
proprietary manufacturing
present owner, Madison
market leading position”.
technology of the product
Capital, in a deal worth
chief executive, said: “I am very
line, which includes TP-90B,
E568m. The takeover is
pleased to be partnering with
TP-759 and TP-95. The
expected to be completed by
Onex given its track record and
purchase provides HallStar
the end of March 2013 subject
experience in our industry. We
with a broader range of
to regulatory approval.
intend to strengthen our global
The deal incorporates
ester technology, principally
Jan Siebert, KraussMaffei’s
presence and build on our
KraussMaffei makes a
used in rubber modification.
range of extrusion machinery,
success at the high-end of the
“The TP trade name is
as well as machines for both
industry.”
known as an integral part of
injection moulding and
polymer formulations and
reaction moulding. Onex will
will significantly expand the
inject $340m into the business.
types of plasticiser-based
“KraussMaffei is a global
KraussMaffei employs 4,000
people worldwide, and had
sales of around E1bn in the
Siebert: “We intend to build
year to 30 June 2012.
❙ www.kraussmaffei.com
❙ www.onex.com
solutions we can provide to
leader in each of its three
on our success at the high-
our customers,” said Louis
segments, with a decades-long
end of the industry”
Pace, executive vice
product line broadens our
CPG adds TimberTech to Azek
global footprint and
US wood plastic composite
International CEO Eric K
industry as both entities
strengthens our portfolio of
(WPC) building products group
Jungbluth said the ultimate aim
manufacture highly engineered,
recognized plasticiser
CPG International has bought
of the acquisition is to merge
outdoor living solution products
brands.”
TimberTech, a manufacturer of
the Azek and TimberTech
that offer exceptional aesthet-
PE-based WPC decking and
operations into one.
ics, performance and longevity,”
president of HallStar.
“Acquiring the TP-series
There will be no changes
in the production location of
railing, from the Crane Group.
“We believe this powerful
the newly acquired product
Pennsylvania-based CPG
combination will not only create
line, ensuring a seamless
International is the parent com-
the largest manufacturer in the
to close this month. No time
transition and eliminating
pany of PVC building profiles
trim, decking and railing
frame has been provided for
any re-approval issues.
and WPC decking manufacturer
market, but will also create a
the merger of the businesses.
❙ www.hallstar.com
Azek Building Products. CPG
premier company in the
❙ www.cpgint.com
he said in a statement.
The acquisition is expected
Sekisui seeks pipe leadership in Japan
However, the acquisition
pipe materials, due to its
Sekisui Chemical is looking to
number of Mitsubishi’s
become Japan’s largest pipe
plastics-related operations,
does not include the cross-
larger production volume;
manufacturer by acquiring the
including several factories in
linked polyethylene (PEX)
greater opportunities for
plastic pipes division of
Japan and Wuxi SSS Diamond
division of Mitsubishi Plastics.
cost-cutting; new technology
Mitsubishi Plastics.
Plastics, which makes joints
The acquisition will allow
Sekisui to take control of a
www.pipeandprofile.com Sekisui said that takeover
developments; and increased
for pipes at its facility in
would give it several things:
global expansion.
Jiangsu Province, in China.
enhanced buying power for
❙ www.sekisuichemical.com
September/October 2012 | PIPE & PROFILE EXTRUSION
5
news
VDMA: machine sales will decline
German plastics and rubber
first few months of 2012 –
sales to decline in 2012, it
machinery sales are expected
proved better than anticipat-
believes they will pick up in
to fall by 2% this year, for an
ed.”
2013. German manufacturers
output of just over E6bn.
However, a 7% growth in
2013 should see output rise to
around E6.5bn next year.
“As late as October last
Sales within Germany are
market shares in 2011: exports
this year and next.
grew by two percentage points
“We expect the domestic
investment climate to remain
year, we had predicted that
positive in 2013,” said
sales would drop by 7% in
Reifenhäuser.
2012,” said Ulrich Reifenhäus-
also expanded their global
expected to be buoyant both
“Many German firms will
to 25.3%, and output by one
percentage point to 22%.
While German manufacturers still dominate exports,
Chinese manufacturers now
er, chairman of the Associa-
reach capacity limits and are
have a lead in terms of output,
tion. “However, business
increasingly planning to invest
with a 30.5% share, says
Reifenhäuser: “We expect
performance in the second
for expansion.”
VDMA.
domestic investment climate
❙ www.vdma.org/plastics
to remain positive in 2013”
half of last year – and in the
Sabic ties
up with
Fraunhofer
Sabic has signed a
multi-year agreement with
While VDMA expects foreign
Arkema sells off tin stabilisers
Arkema is to sell off its tin
are used in PVC production,
and the Beijing plant in China
stabiliser business to US-
much of which is
will be transferred, while part
based chemicals and plastics
company PMC.
With this proposed
used in the construction
of the Vlissingen site in the
sector. As part of Arkema’s
Netherlands that is dedicated
Functional Additives business
to tin stabilisers will be run by
Arkema on behalf of PMC.
Fraunhofer, the German
divestment of its organometal-
unit, this organometallics
research organisation, to
lic products, including
activity reported sales of
develop “advanced
Thermolite tin stabilisers,
approximately E180m.
technologies” in various
Arkema is continuing to
areas of research, including
refocus on its speciality chemi-
people at four industrial sites
employment with the new
lightweight construction
cals business.
around the world: the Carroll-
company.
ton and Mobile plants in the US,
❙ www.arkema.com
and renewable energy.
Thermolite heat stabilisers
The project will affect 234
It is anticipated that all
involved employees in the sold
business will be offered
Sabic is particularly
including polymeric
Polyplastic signs deal with Talis
materials and composites.
Russia’s Polyplastic Group and
water, gas and heating
look forward to introducing
The company also has a
Germany’s Talis Group have
infrastructure solutions.
Talis products through
strong interest in solar
begun a strategic cooperation,
energy technology.
to bundle Talis products as
and CEO of Polyplastic, said:
part of Polyplastic’s offerings.
“By enlarging our product
interested in fields such as
light weighting products,
Ernesto Occhiello, Sabic
executive vice president of
6
Polyplastic supplies
Miron Gorilovskiy, president
offering with Talis high
Polyplastic’s network.”
Talis brands include Erhard,
Raphael and Belgicast.
Separately, Polyplastic has
technology and innovation,
thermoplastic composites and
technology valves and fittings,
commissioned three new
said: “We have built
polyethylene (PE) pipe in
our customers will get the most
extrusion plants in Kazakh-
networks of research
Russia and CIS countries,
complete, efficient solutions in
stan, to produce around 30,000
alliances with key global
while Talis designs and
the water, gas and heating
tonnes/year of its Arystan
partners, and are proud to
manufactures valves and
infrastructure networks in
corrugated plastic pipes in
partner with Fraunhofer.”
fittings. The two intend to
Russia and CIS countries.”
❙ www.sabic.com
❙ www.fraunhofer.de
strengthen their business rela-
Kris Holla, chief sales
tionship by offering integrated
officer of Talis, added: “We
PIPE & PROFILE EXTRUSION | September/October 2012
order to meet rising demand.
❙ www.polyplastic.ru
❙ www.talis-group.com
www.pipeandprofile.com
news
Separate units for extrusion
Reifenhäuser of Germany has
häuser Extrusion Technology,
concentrates on the develop-
split its extrusion business into
which specialises in the
ment and manufacture of cast
two independent companies,
development and manufacture
film lines, polishing stack
allowing them to focus on their
of extruders and WPC lines. It is
systems, coating lines, dies
different market requirements.
headed by Tim Pohl (pictured).
and winders. It is led by
The activities of the
The Cast Film business
Extrusion Center business unit
unit, which is now Reifenhäus-
are now dealt with by Reifen-
er Cast Sheet Coating,
Pexco begins new Odyssey
Jochen Hennes.
❙ www.reifenhauser-et.com
❙ www.reifenhauser-csc.com
Pipes JV
in Finland
Odyssey Investment Partners
facilities across North
and will continue to lead the
Finnish pipe companies
has acquired Pexco – a leading
America.
company.
Uponor and KWH have
Shillingford said: “We are
supplier of custom extruded
Craig Staub, managing
plastic products – from Saw
principal of Odyssey, said:
very pleased to combine
combine their systems
Mill Capital. Financial terms of
“Pexco is a well-positioned
Pexco’s experience with
businesses. Uponor Infra
the transaction were not
company in the custom
Odyssey’s understanding of our
will concentrate on
disclosed.
segment of the extrusion sector
industry and end markets.”
northern Europe.
Pexco, which is based in
and operates in attractive end
Pexco made four acquisi-
formed a joint venture to
The partners said it
Atlanta, Georgia, is a leading
markets. It is an excellent
tions last year: retail products
would improve efficiency
player in custom extrusion,
platform for expansion through
extruder RDC Cytex of the US;
and profitability.
focused on industrial,
organic growth and strategic
custom profile extruder
commercial and medical
add-on acquisitions.”
AllWest Plastics; Multitube
KWH, said: “We will
Medical Devices of Mexico; and
establish a new structure
Patrician Products, which
that aims at a better
applications. Its other services
The Pexco management
Peter Höglund, CEO of
include design, prototyping, die
team, including CEO Neil
building, sub assembly and
Shillingford, CFO Dennis Fink
makes garden products.
capacity utilisation.”
supply chain management.
and COO Sam Patel, have
Pexco has 10 production
invested alongside Odyssey
❙ www.pexco.com
❙ www.odysseyinvestment.com
❙ www.uponor.com
❙ www.kwhpipe.com
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Extruder technology | machinery feature
Co-extrusion is big business in pipe and
profile extrusion, and is something
that suppliers are all clamouring
to supply. Lou Reade reports
Layered
approach
An emerging trend in pipe and profile is co-extrusion,
are increasingly using dry blends from materials with a
KraussMaffei
usually in order to save money.
low additive proportion, but a high filler proportion. The
co-extruders
type of application, and the available production space,
are aimed at
Rather than extruding products from 100% virgin
resin, for example, they can now make the ‘core’ of the
product from recycled material, which can help to slash
costs.
KraussMaffei Berstorff has developed a number of
A co-extruder can be used to process both the core
of new types of
layer and the top layer. For example, a conical KMD 63
window profile
K/P co-extruder containing a parallel twin-screw
co-extrusion models, aimed at the production of new
extruder extrudes the core, and can also be used in
types of window profile – which are increasingly moving
layer technology to produce the outer profile layer.
towards greater use of recyclables and fillers.
The systems help profile manufacturers to reduce
the production
determine the extruder arrangement.
The company says that its concept of parallel and
conical twin-screw extruders ensures optimum melt
material costs, and ensure economic production. Its
homogeneity and allows processing of many different
recently launched KMD 53 K/P, for example, completes its
formulations with a single screw geometry. When
series of conical twin-screw extruders for medium output.
designing the conical screws, the company paid close
“Our co-extrusion models help processors to
attention to the increased requirement relating to the
manufacture a premium quality end product using
pressure stability of the conical extruders. The screws
cost-effective raw materials,” said Peter Oswald,
are molybdenum-plated and, in combination with the
director of the profile extrusion product group at
deep-nitrided barrels, provide active wear resistance –
KraussMaffei Berstorff.
especially during processing of recyclables and dry
He says that the company’s machine combinations
are suited to window profile production based on the
blends with high filler proportions.
All models, whether parallel or conical twin-screw
standard market technologies – core technology, layer
extruders, exhibit modularity, flexible processing
technology and combination technology.
technology and ease of handling.
The use of fillers is growing, as processors use them
The conical co-extruders are available as a standalone version, but can be easily moved around the
external layer of a colourfast virgin material. Producers
factory floor.
www.pipeandprofile.com
▲
to produce the profile core that is covered by a thin
September/October 2012 | PIPE & PROFILE EXTRUSION
11
machinery feature | Extruder technology
wheels and pivot mechanism. This feature allows the
extruder to be moved quickly into the correct processing position depending on the downstream being used.
This improves the flexibility and ease of use of
the machine.
The system was completely ‘wet tested’
under load before shipment, to allow full
drive calibration and programming, tuning of
temperature controllers and confirmation of
screw performance.
“The machine arrived on time and
start-up was very easy and fast,” said Kris
Tejeswi, Plastics Engineer at Miller Edge. “We
had the machine in full production within two days of it
arriving at our plant.”
Piggyback ride
High Tech Extrusion has
Spirit Design,
also developed a number of
Pivotal moment
co-extrusion options. The
Omnia line its
American Kuhne recently
core of profiles or of pipes
new look, was
supplied Miller Edge with a
is made from recycled or
also respon-
customised extruder that
other cost-effective
sible for the
is designed to pivot 45˚
material. Material costs
Panther fire
about a fixed point, to allow
can be reduced by 30% in
for in-line or co-extrusion
the production of three-
positioning.
layer-pipes, it says.
which gave the
engine
In its ‘piggy back’
Miller Edge manufactures emergency stopping
solution for profile
devices for motor-driven
co-extrusion, a conical
doors and gates, as well as
extruder (Con 40 or 50, or
a full line of safe-guarding
the CO.32 single screw
products for perimeter,
co-extruder) is mounted on
area and machine
the main extruder. With its
guarding.
newly developed clamp
system for the piggy back
The Ultra 2.5in 24:1 L/D
solution, adjustment of the co-extruder is possible in all
allows it to be run with an inline head or coex- cross-
directions (up, down, side and angular) allowing perfect
head by pivoting the extruder on specially designed
positioning.
2013
Pipes in
I n f r a s t r u c t u re
Market trends, new products and technical developments
in plastic pipes for infrastructure applications
9-11 April 2013, Hotel Nikko,
Düsseldorf, Germany
12
PIPE & PROFILE EXTRUSION | September/October 2012
Organised by Applied Market Information Ltd. (AMI)
▲
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machinery feature | Extruder technology
A customised
extruder
helped Miller
Edge to pivot 45
degrees about
a fixed point, to
This version is cost-effective and saves lots of space.
It can also be mounted on non-Theysohn extruders.
High Tech Extrusion recently helped a UK customer to
modify their old extrusion lines into co-extrusion lines.
It did this by mounting a conical extruder Con 50
‘piggyback’ on the existing (competitive) extruder. The
allow for
customer was highly satisfied with the result. The
in-line or
requested output was achieved, and shortage of space
co-extrusion
positioning
at the plant was no longer an obstacle.
The output with the Con 50 conical extruder as
co-extruder is 125kg/h for PVC window profiles and
150kg/h for rigid PVC profiles. To increase output, High
Tech is now working on a solution for the conical
extruder Con 63 as co-extruder. In this case a successful mounting depends on the size of the main extruder.
The company also offers a ‘pillar’ arrangement, in
which the extruders are positioned next to one another
and the co-extruder is mounted on a pillar. High Tech
offers solutions for the single screw coextruder CO.32
as well as the conical extruders Con 40 and 50, and is
output of 400-1600kg/h can be achieved for PVC pipe
working on a construction for the Con 63.
co-extrusion.
There is also a third arrangement, for co-extrusion
The CO.32 single-screw extruder can be used for
of pipe and siding. Both extruders are positioned next to
profile- and pipe extrusion with rigid PVC, soft PVC, PA,
each other, but the co-extruder is mounted on wheels
PMMA and TPEs.
so can easily be moved. This solution is suitable for all
existing extruders in various combinations. Maximum
Control option
output for PVC siding co-extrusion is around 1400kg/h
At the same time, High Tech’s TEC 4s extruder control
(though 1500kg/h is possible, depending on the type of
system TEC 4s, developed in cooperation with Siemens,
profile). The line runs at 45m/min.
combines simple handling and efficient control.
Depending on the combination of extruders, pipe
head, pipe dimension, pipe material and formulation, an
It has recently been supplied as an option for
extruders, but can also be ordered as a retrofit kit for
High Tech and Theysohn Extruders.
Parallel lines
Weber of Germany offers a range of extruders, as well as complete pipe
and profile extrusion lines.
Its range of extruders includes DS series parallel twin screw extruders as well as CE
series conical twin screw extruders, ES series single screw extruders
and the NE grooved feed series of single screw extruders.
The standardised, inexpensive single screw extruders of the Super-
An operating terminal, optimised for heavy industrial
conditions, allows comfortable control of the whole line
in combination with HMI software, while a 19in touchscreen guarantees easy operation – with large soft-keys
and intuitive colour and graphic design.
The core of the system is a fanless – and therefore,
maintenance-free – industrial PC. Communication
between the TEC 4s and all drives, peripheral devices
and downstream equipment works through the Profibus
system. Operational reliability and short downtime are
achieved by simple wiring, because of high quality
Edition ES-SE series can be supplied on short notice, and are suitable for
components, an analysis program and remote mainte-
the extrusion of a variety of pipes and profiles.
nance via LAN or WAN.
The conical twin screw extruders and the single screw extruders are
The main advantage is that in the vast majority of
available as standard or tailor-made CE Z or ZE series co-extrusion
cases, customers can maintain the system by them-
units. Two main extruders in space-saving duo arrangement can be
selves, saving the visit of a Theysohn technician. A few
offered together with the twin strand downstream unit for production of
simple steps, which do not required advanced technical
window profiles, for example. If needed, these extruders can also be
know-how, are enough to change frequency converters
equipped with co-extruders as a ‘piggyback’ version.
or CF-cards – helping to avoid production downtime.
It also supplies twin screw extruders for the extrusion of natural fibre
composite materials that can be processed either as compound or dryblend.
14
PIPE & PROFILE EXTRUSION | September/October 2012
Software updates can be installed quickly and easily.
The system boats two independent operating
www.pipeandprofile.com
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RECOMMENDED READING
Our selection of the latest titles and essential reference works for the pipe & profile industry
Trenchless Technology of Piping:
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Please check the Plastics Information Direct website for current prices and shipping charges.
Extruder technology | machinery feature
systems, in the shape of Windows XP Embedded and
WinAC RTX. In case of emergency, the main motor can
be started independently from the PLC.
There are also a number of productivity advantages,
says the company. There is access to remote maintenance via the internet or intranet, as well as a quick
connection system of tooling – with one common socket
for both electrical energy and temperature sensors.
Because heating current is monitored by current
transformers, this allows for quick detection of
damaged heating zones.
High Tech Extrusion, which consists of Theysohn,
Technoplast, Topf and Extruder-Komponenten Salzgitter, is an ‘all-in-one’ provider that supplies extrusion
lines, tools and pipe heads.
Other recent development include the RK Stream-
Railway trains), the ‘Panther’ airport fire engine from
High Tech’s Con
liner pipe head and the Omnia series extrusion line. The
Rosenbauer, and a self-assembly tractor called ‘Ox’.
40 piggyback
version on a
look of the new Omnia line was masterminded by
Vienna-based company Spirit Design, which had a brief
Click on the links for more information:
TTS 88 profile
to set the line apart from its competitors. Extrusion
❙ www.kraussmaffei.com
❙ www.americankuhne.com
❙ www.ht-extrusion.com
❙ www.hansweber.de
extruder, with
lines are usually highly functional, with aesthetics some
way down the list of priorities. Among Spirit Design’s
other designs are the ÖBB Railjets (Austrian National
new clamp
system
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Downstream equipment | process feature
Handle with care
It’s debatable as to how far you can take take the
concept of ‘downstream equipment’. Does it stop with
coiling – as the pipe is on the roll – or can you extend
the concept to post-post finishing processes? Should
you include the boat that tows the pipes to their final
destination, for example?
Whatever the merits of each step, there is a huge
variety of equipment on offer – which variously per-
Once your product is out of the die,
there is plenty more handling to be
done – all the way along the line.
Lou Reade reports
forms cooling, coiling and control.
In a recent paper published in the Journal of
www.pipeandprofile.com
obtain exact analytical solutions for the solidification of
plastic pipe for two outer-wall cooling configurations:
supplied a
30-tonne
under-roller
isothermal and non-isothermal.
rebatch line to
“In plastic pipe manufacturing, it is important to
determine how long it will take for molten extrudate to
a major
solidify,” write the researchers. “The solidification rate
umbilical
governs not only the quench tank length, but also the
manufacturer
wall thickness distribution – by delimiting how much
sag occurs to the molten interior of the pipe.”
They say that their calculations will help plastics
engineers to design a better quench tank – the cooling
chamber that either submerges the extrudate in cold
water or exposes it to a cold water spray.
Worked examples in the paper show plastics
engineers how to use the results.
▲
Advanced Engineering, researchers at the University of
Wisconsin-Madison in the US have revealed details of a
method that analyses the quenching of plastic pipe.
Extruded plastic pipe emerges from an annular die
as hot molten plastic – which must be solidified. This is
usually done by plunging it into cold water, or spraying
cold water onto the outer surface. This quenching
solidifies the plastic by taking its outer wall temperature down to that of the cold water.
The paper expresses the solidification time as a
function of solidification temperature and pipe radius.
The researchers have devised an equation that allows
pipe extruders to determine the residence time that is
required for solidifying the pipe – or to cool it to a
certain temperature below the melting point.
PCT has
The researchers solved the equation of energy to
September/October 2012 | PIPE & PROFILE EXTRUSION
19
process feature | Downstream equipment
Zumbach’s KW
Coiled up
operator simply pulls a release pin, rotates the unit 180
13Trio detec-
PCT, based in Newcastle in the UK, recently supplied a
degrees and switches control wires from one puller
tors can
30-tonne under-roller rebatch line to one of the world’s
section to the other. Operator-interface readouts and
accurately
major umbilical manufacturers.
control calibration change automatically to match
capture lumps
Umbilical is a composite cable used by the offshore
whichever drive system is being used.
and neck
industry to link the various elements of undersea oil
downs in a
and gas production systems. It can comprise thermo-
cutting accuracy and for the pressure exerted on the
variety of
plastic hose, steel tubes and electrical cables.
tubing being extruded.
products
The under-roller rebatch line can rewind hose
Both puller sections are servo controlled for speed,
“Traditional belted pullers are used for many
between two reels, allowing the user to supply either a
applications because they contact the extruded tubing
specific length from one drum to another, or to recoil a
over a larger area,” said Bob Bessemer, sales manager
badly-wound drum. The line consists of two take up/pay
for medical extrusion at Conair. “Belts need to exert
off units facing each other. A single traverse unit
less pressure in order to achieve a satisfactory grip on
controls the feeding of the product to the take-up drum.
delicate medical tubing.”
The lines can be run in either direction.
A clever feature of the under-rollers is the ability to
However, when making extremely thin flexible tubing
of the order of 0.008in (0.2mm) diameter, many
swap the traverse unit from one machine to the other
extruders prefer a puller that pinches the product
so that either machine can act as the take-up. The
between two small rollers. The new Medline system can
traverse unit also includes a dancer arm which provides
be used both in the lab and in production situations
feedback to trim the speed of the pay-off unit. The units
where it is necessary to switch between one configura-
are designed to take drums up to 4m in diameter by
tion and the other.
2.6m wide and a weight of up to 30,000kg.
The rebatch line is compliant with EU health & safety
The new convertible puller is part of a family of
equipment developed to meet the needs of extruders
standards and has been fitted with a number of safety
who make precision medical tubing, including multi-
features. These include safety fencing which completely
lumen microbore tubing for heart and brain catheters.
encloses the line and sensors fitted to entrance points
Controls receive constant feedback from inline gauges
which automatically reduces the speed of the winding to
so that the puller servo motors can be adjusted to
safely allow operators to work within the area.
maintain correct dimensions, including internal and
PCT, which has subsidiaries in the US and China,
outside diameters and cut-to-length accuracy. Both
designs and supplies coiling, handling and packaging
belted and pinch-roll units include a small servo motor,
solutions for flexible products such as plastic pipe,
in-line planetary-gear reducer and digital controller to
sub-sea umbilical and power cables.
automatically establish and maintain the gap between
the puller contact surfaces and the consequent
Pulling power
A convertible puller/cutter – part of the Medline family
The cutter portion includes a standard positional servo
of products from Conair – combines two machines in
drive system, which provides cut response repeatability
one. A conventional belted puller section, used for most
within ±0.1ms – a ten-fold improvement over conventional
tubing applications, is mounted opposite a pinch-roll
velocity-based servo systems, says Conair.
puller that can control very small-diameter tubing.
To switch from one set up to another quickly, an
20
pressure on the tubing.
PIPE & PROFILE EXTRUSION | September/October 2012
Cut response repeatability relates directly to product
cut-to-length accuracy, which may need to be as tight
www.pipeandprofile.com
Our technology, your vision
In-line Profile
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Any pipe, tube, profile
PROFILEMASTER®
Advanced vision technology (light-section). Full profile
contour measurement. Profile and critical dimensions,
radii and angles can be programmed (teach-in) and
monitored. For products up to 300 mm (11.8 in.).
Contact us – and get the future under control:
askme@zumbach.ch
Zumbach Electronics
Switzerland, Argentina, Benelux, Brazil, China, France,
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customersatisfaction
process feature | Downstream equipment
McElroy’s
latest model in
its TracStar 500
series of
as ±0.005in (±0.13mm). Fast response is especially
important as extrusion rates increase. The cutter blade
descends from above, making it easier to feed cut
tubing to discharge conveyers, and the cutter guards
all-terrain
are clear so that operators can easily see the condition
fusion ma-
of the blade or the presence of contamination.
chines will butt
fuse pipe sizes
of 6-20in
Checking quality
The new line of KW 13Trio detectors from Zumbach
Electronics can accurately capture lumps and neck
downs in a variety of products including optical fibres,
cables, tubes and hoses.
The KW 13Trio’s compact design allows it to be
integrated in any extrusion line or rewinding process.
The measuring field is dimensioned so that, during
start-up, even extremely big lumps will pass through
smoothly. Its open design enables quick, easy threading
of the product without halting production.
A unique measuring principle and complex optics
solution ensures immunity to stray and intense light,
while providing high detection accuracy and identification of lumps and neckdowns in the micrometer range.
Thanks to a separate BAE 2-KW operating and
display unit, the KW 13Trio can be fully operated and
and lowered into tight spaces for in-ditch fusion.
A major addition on the Series 3 is an economy
configured at the device. The BAE 2-KW can be fixed at
throttle setting that saves fuel by throttling down when
the operator station with a mounting bracket, or
idle. McElroy also added hydraulic clamping as
positioned on the table.
standard, reducing operator fatigue and increasing
At the same time, it has made a number of additions
productivity. Power for the heater is supplied by an
to its Profilemaster family. The PMM 30, 50 and 80
on-board generator, while a hydraulic-pump system
profile and shape measurement systems are the latest
driven by the engine provides the power for the facer,
models in the range, enabling measurement systems
dual-speed track system and more. Dual hydraulic pipe
using the principle of light section and machine vision.
lifts help to load and unload the pipe into the carriage.
Zumbach also offers its Wallstarter, which can
With the heater and facer now mounted on the
deliver significant cost savings. With its non-contact
machine, operators no longer have to manually place
ultrasonic measurement technology, wall thicknesses
the heater or facer in the carriage during the fusion
can simultaneously be measured and displayed on 4, 6
process.
or 8 points. Thanks to the continuous quality control,
material savings can be achieved during the entire
production process. To integrate complex optimisations
At the same time, its systems have recently been
used to install two water pipelines in the UK.
On the east coast of England, 63km of 560mm-diam-
or automatic control loops, customers can easily
eter PE pipe has been fused together to bring water to
upgrade to a Wallmaster system.
Boston – which has nearly doubled its population in the
last 10 years.
Mobile fusion
phase, to construct the last 20-plus kilometres of pipe,
TracStar 500 series of all-terrain fusion machines.
will occur next year.
It will butt fuse pipe sizes from 6in IPS to 20in OD
“We’re trying to do as much of this project as
(180-500mm). McElroy claims it was the first fusion
possible with butt fusion,” said Andrew Young, project
machine to be mounted on a track system, making it
manager for JN Bentley, which is leading construction.
mobile in almost any terrain.
“The majority of the project will be open trench, with a
The fusion machine features a facer and heater that
are indexer-mounted and powered by the TracStar 500.
An automatic version of the TracStar 500 Series 3 is also
available, in which the fusion carriage can be removed
22
The project began in spring this year. The second
McElroy recently launched the Series 3 model in its
PIPE & PROFILE EXTRUSION | September/October 2012
few crossings directionally drilled.”
The company is using McElroy’s TracStar 900s and
MegaMc PolyHorses to connect the pipe sections together.
To fuse the 560mm pipe on site, inserts were placed
www.pipeandprofile.com
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process feature | Downstream equipment
in the north of England, which carry water to 900,000
people in Cheshire and Merseyside.
The lines have been updated with swagelining, using
Radius PE100 SDR 51 pipes. The pipe sections were
joined together with MegaMc 1648 machines.
“We need 8 welds a day to make it pay,” said Mike
Baker, assistant project manager with Denholm
Pipecare. “At times, we’ve been doing 10 welds a day.”
The process takes the PE pipeline and, using
specialised equipment, reduces its natural diameter of
the pipeline to fit within the existing line.
To create the polyethylene liners, workers from
Denholm Pipeline fused together PE100 pipe materials
at several different sites. Access holes were created at
Zumbach’s
different places to insert the PE liner into the older
Profilemaster
pipelines.
profile and
Click on the links for more information:
shape measurement
within the jaws of the TracStar 900 to bring the inner
systems can be
circumference of the jaws down to the 560mm pipe size.
used for a
This helps grab the pipe tightly and re-round the pipe
variety of
for a better fusion process.
materials
It has also helped to modernise ageing water pipelines
❙ www.wisc.edu
❙ www.pipecoil.co.uk
❙ www.conairgroup.com
❙ www.zumbach.com
❙ www.mcelroy.com
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The world’s biggest plastics exhibition – Düsseldorf’s K show – takes place
next year. We will be covering the event with lots of special
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truly global magazines are the perfect vehicles to let international
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The international conference on advanced elastomer, composite and
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23-25 October 2012
Millennium Gloucester Hotel,
London, United Kingdom
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PE100 | materials feature
Hundred club
HDPE pipe, particularly the PE100 variety, can find itself
used in the most out of the way places. GPS PE Pipe
Systems of the UK has supplied piping for the Inver
Hydro Dam, one of the most remote and largest private
hydro schemes in the UK.
Scotland’s Western Isles are an ideal location for
hydroelectric power, and for the past 30 years the Inver
estate on the Isle of Jura has relied on a small hydro
PE100 leads the way for demanding
high pressure piping – sometimes in
the remotest of locations.
Lou Reade reports
generator. The generator’s age, and the need to plan for
future increases in energy demand, led to a decision to
replace the current plant. However, the only financially
“The pipeline had to be easy to install and, once in
viable solution was to connect the estate to the
the ground, had to be long-lasting and robust so that we
electricity mains six miles to the south and export any
hopefully never have to see it again,” said Inver Hydro’s
surplus generation.
John Lithgow.
Delivered by Inver Hydro, the scheme involved taking
piping fulfilled this requirement, whilst ensuring that
directing water into a local loch, where a 280m dam
installation was rapid and simple, with minimal
raises the water level by 3m. From here, the water
requirement for specialist plant.
with a pressure rating that closely matched the actual
The installation of the new hydroelectric plant had to
head along the penstock to achieve the most cost-effec-
respect the local ecology, landscape and environment,
tive solution.
with minimum maintenance.
www.pipeandprofile.com
power scheme
in Scotland
GPS supplied 2300m of black 1200m, Excel piping
penstock (pressurised pipeline) to a new powerhouse.
so had to be robust enough to last for at least 50 years
for use in a
hydroelectric
The strength and flexibility of GPS’s Excel PE100
water from four catchments and three concrete weirs
travels down a new, underground 2,500m HDPE
GPS has
delivered pipe
When the project is completed in October 2014, the
maximum output will be 1970kW (7.6 gWh/year),
September/October 2012 | PIPE & PROFILE EXTRUSION
27
materials feature | PE100
Fresh approach
Pressure’s on
A PE100 grade of HDPE, with high stress crack resistance, has been
when producing the pipe, it says.
used in a fresh water pipeline in China.
BorSafe HE3490-LS-H from Borouge was specified for the water
Vestolen A Rely bimodal HDPE grades from Sabic can
meet the stringent requirements for typical pressure
pipes, as well as helping customers with energy savings
Two grades of the material are available, both of which
can produce pressure pipe that meets the PE100
feeder main for the new Tianjin Eco City in China. The local water
standard. Vestolen A Rely 5924R delivers good low sag
company was keen to use PE100 for the complete pipeline in order to
performance for large-diameter pipes and pressure pipes
speed up installation, however they were concerned about the damage
with a low standard dimension ratio (SDR). Vestolen A
that could be caused by the directional drilling operation for the section
Rely 5922R helps customers meet the stringent slow
under the Ji Canal.
crack growth requirements for pressure pipe, enshrined
To overcome concerns about damage that could be caused by directional drilling (for the section under the Ji Canal), the contractor used pipe
in PAS (Publicly Accessible Standard) 1075.
Certification to PAS 1075 enables the grade to be
made from BorSafe HE3490-LS-H for this section, to provide high
used for pipes intended for installation using the most
resistance to any surface damage that could be caused by installation,
demanding techniques, including new trenchless
says the company.
methods such as guided boring and horizontal direc-
The same grade was also used by the Kuwait Oil Company in order to
tional drilling.
protect some of its water injection lines. The pipe lengths were welded
These methods have a reduced impact on the
and pressure tested, then inserted into the steel pipe using swagelining
environment, but they are more demanding of pipe
technology.
properties, since surface damage during the installation
process is more likely to occur.
making Inver Hydro one of the largest privately owned
hydro stations in the UK.
At the same time, GPS has supplied PE piping for the
Apart from their good mechanical properties, the
grades could help processors to make energy savings,
thanks to their rheological and morphological properties
water and gas infrastructure at Premier Inn’s new
– created through a combination of proprietary catalysts
£125m Stansted Airport hotel.
and fine-tuned reactor and extrusion technology.
The hotel is close to existing water and gas mains,
“A company already operating a line at full capacity
but there was no existing pipe work connecting the site
could be able to increase output by as much as 16%,
to the utilities, so the project’s subcontractor HJ
compared with commonly used bimodal HDPE, while
Services laid 192m of Excel (PE100) water pipe and
reducing electricity consumption,” said Jean Engels,
312m of PE80 gas pipe.
business manager for HDPE at Sabic.
Main contractor McAleer & Rushe specified PE pipe
“On the other hand, a pipe producer that does not
for the installation due to its proven performance,
need to raise production can realise energy savings by
competitive cost and durability. Both gas and water
running at the same speed. Pipe size will also play a
pipes were laid in an open cut installation with lengths
part in determining exactly how big the savings are.”
of pipe welded together to form strings before being
lowered into the trench.
For the water pipe installation, HJ Services used a
These features have been requested by the market,
he says.
The grades are currently available in black, but Sabic
combination of 125mm and 90mm blue Excel piping in
is developing two coloured grades with enhanced
SDR17 to manage varying levels of pressure, which
resistance to slow crack growth propagation, which will
reaches six bar in some areas of the site.
be commercially available in 2013.
As gas pressure to the site is low, the contractor
used a larger 180mm diameter yellow PE80 pipe in
Cracking test
SDR17.6.
Sabic has also developed a method for high-speed
Dan Morgan from HJ Services said: “One of the many
advantages of using PE pipe is that we can adjust the
used for pressure pipes. It says that its strain hardening
diameter and SDR of the pipe for different parts of the
method is faster and more cost-efficient than traditional
site to adapt to the available water or gas pressure. The
methods of obtaining data on long-term performance in
networks have been fast and trouble-free to install and
pipes. In addition, it does not require a special notched
connect up to the mains and will provide a safe and
specimen or detergents.
reliable gas and water supply to the hotel for a service
life of at least 100 years.”
28
evaluation of the slow crack growth resistance of HDPE
PIPE & PROFILE EXTRUSION | September/October 2012
“It is easy to implement in laboratories, is suitable in
the development of new grades by researchers, and is
www.pipeandprofile.com
PolymerFoam2012
International conference on blowing agents and foaming
technology for thermoplastics and elastomer
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HERE FOR
DETAILS
October 9-10, 2012
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Sealed Air Corporation &
Reedy International Corporation
DoubleTree by Hilton Hotel Newark Airport,
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materials feature | PE100
Two new PE100
very valuable as a batch release test for resin suppliers.
grades from
It saves time, money and energy,” said Lada Kurelec,
Sabic meet
technical marketing manager for HDPE at Sabic.
stringent
The company believes that greater use of the
requirements
technique will accelerate adoption of the latest Vestolen
and can save
A Rely grades of bimodal HDPE that are aimed at high
energy
pressure pipe.
International quality authority Kiwa Technology, of
Apeldoorn in The Netherlands, has adopted the method.
“The test delivers reproducible results which
correlate with results of time-consuming traditional
slow crack growth tests – but in a much shorter time,”
said Frans Scholten, an expert on material testing at
Kiwa Technology.
“We use the test to provide pipeline owners with
relevant information about the long-term quality of their
existing polyethylene gas and water distribution
networks,” he added.
Click on the links for more information:
❙ www.gpsuk.com
❙ www.sabic.com
❙ www.borouge.com
Intelligent
Additive
Solutions
•
•
•
•
•
Superior Viscosity Control
Improved Mold Release
Higher Loading of Fillers
More Uniform Dispersion
Faster Throughput
A Product Line as Varied as Your Business
Struktol’s extensive product line of Intelligent Additive Solutions
are ideal for today’s demanding polymer industry. Let one of our
professionals formulate a solution that’s right for your business.
www.4struktol.com
Struktol is represented in most European countries by VELOX GmbH, Germany.
Struktol 330.928.5188 / customerservice@struktol.com | Velox +49.40.369688.0 / info@velox.com
inerals in
Compounding 2012
Global conference on minerals as additives, pigments and fillers in polymers
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PROGRAMME
FOR MORE
INFORMATION
PLEASE CONTACT:
Jessie Ceriello,
Conference Coordinator,
jc@amiplastics-na.com
PH: +1 610 478 0800
FX: +1 610 478 0900
November 27-28, 2012
Hyatt Regency Atlanta,
Atlanta, Georgia, USA
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AMI’s Guides to
THE THERMOPLASTICS PIPE
EXTRUSION INDUSTRY IN
EUROPE, NORTH AMERICA AND SOUTH AMERICA
Three unique reports give you an essential understanding of the pipe extrusion
industry and its key players in the European and American continents.
•
•
Overview of the thermoplastics pipe market
Company information on 1020 production sites manufacturing thermoplastics pipes
AMI’s Guide to
The Thermoplastics
Pipe Extrusion Industry
in Europe
490 sites
Thermoplastics pipe extrusion represents a significant
market for polymer materials in Europe and America.
However this market is affected by the fortune of the
building industry and the investments governments
are prepared to make to improve their infrastructures.
The trends in polymer usage vary across the regions
and are affected by a number of factors. These three
different reports will provide you with an inside
knowledge of the pipe extrusion industry in these
different regions of the world.
In each guide and for each region you will find the
following information:
AMI’s Report on
The Thermoplastics Pipe
Extrusion Market
in North America
315 sites
• Market data and analysis
• Company information
Production plants are listed alphabetically with
their full addresses, telephone, fax numbers, email
and website.
• Managerial contacts
• Polymers processed
• Type and size of pipes manufactured
AMI’s Guide to
The Thermoplastics Pipe
Extrusion Industry
in South America
215 sites
Applied Market Information Ltd.
For more details or to order click on each
title or contact Régine Futter on:
Tel: + 44 117 924 9442
Fax: + 44 117 989 2128
Email: sales@amiplastics.com
www.ami-publishing.com
Trenchless technology | process feature
Making the cut
Trenchless methods that involve the installation of a
new pipeline, or ‘whole pipe replacement’ include
horizontal directional drilling (HDD), sliplining and pipe
bursting. They are characterised by the installation of a
new pipeline or conduit that does not derive pressure
capacity, strength or design life from a previously
installed ‘host’ infrastructure.
In a recent technical paper, Tom Marti and Richard
Botteicher of US-based Underground Solutions say that
Trenchless pipe installation is
becoming more commonplace,
thanks improvement in factors such
as materials and software.
Lou Reade reports
whole pipe replacement and rehabilitation methods
have seen a huge increase in the water and wastewater
industry thanks to advances in installation technologies
and pipe materials – such as fusible PVC pipe (FPVCP).
FPVCP as a pipe material and joining method has
wastewater industries.
An example is seen in an installation that Under-
pipe was robust
ground Solutions did for Middlesex Water Company,
enough to be
helped to increase the capability and awareness of
which recently completed the planning, design and
whole pipe trenchless replacement and rehabilitation
construction of a new 24in, 5,800 ft long water main to
technologies in the water and wastewater industries,
replace an existing 24in cast iron water main that was
say the authors. The material can stretch the limits of
more than 100 years old.
trenchless methods – such as horizontal directional
Alternative construction methods for crossing the
drilling (HDD), sliplining, and pipe bursting – thanks to
4,800 ft wide Raritan River were evaluated. These
its tensile and bending properties.
included open-cut trenching, micro-tunnelling, pipe
Using thermal butt-fusion joining technology with
used in a
horizontal
directional
drilling project
that crossed
the Raritan
River
jacking, conventional tunnelling and horizontal direc-
PVC piping has had a major impact on waterworks
tional drilling (HDD). Factoring in construction schedule,
projects. The combination of a familiar piping material
cost, sustainability, impacts to the environment and
with a joining method that lends itself to cutting edge
marine traffic, HDD and FPVCP were recommended for
trenchless installation methods has seen rapid
the river crossing. The final design consisted of an HDD
expansion in application and use in the water and
crossing, approximately 5,365 ft long, using 24in FPVCP.
www.pipeandprofile.com
Fusible PVC
September/October 2012 | PIPE & PROFILE EXTRUSION
33
process feature | Trenchless techhnology
construction methods are documented, the engineering and contracting industries are paying closer
attention to this alternative construction method,” said
Tony Radoszewski, executive director of PPI.
Both software packages are applicable for use in
analysis and design of PE pipe systems for fuel gas
lines, or for municipal pressure and non-pressure
The completion of this
applications.
PPI-BoreAid was developed by BoreAid technical/
HDD and pipe pullback makes
it the longest FPVCP pullback for a
diameter of 24in or more completed to date, say
software consultant Karl Lawrence and Ali Bayat, who
is assistant professor at the University of Alberta.
“The software allows the user to select the type of
the authors.
BoreAid, which
is also
“FPVCP is robust enough to complete HDD inser-
PE, the pipe classification, and the application in order
to design pipelines installed by horizontal directional
tions of this length and depth,” they said.
available in a
drilling (HDD),” said Mark Knight, executive director of
simplified
Software aids
the Center for the Advancement of Trenchless Technol-
version from
The Plastics Pipe Institute (PPI) has developed two
ogy (CATT) at the University of Waterloo in Ontario,
PPI, helps in
online software aids to help in the design and installa-
Canada. “It is a useful evaluation aid that blends all
the design and
tion of polyethylene (PE) pipe.
available industry guides.”
installation of
trenchless pipe
The PPI-BoreAid tool uses calculation methodology
PPI-BoreAid software simplifies the design process
of complex calculations for trenchless applications of
and framework as developed and used in BoreAid – a
PE pipe used in gas distribution, water and sewer
more comprehensive HDD design tool.
“The design of PE pipe systems is being simplified to
systems. Details of the project and pipe can be entered
into the tool in order to assess deflection, critical
assist designers and owners,” added Radoszewski.
collapse, pull back force and pullback force.
“The design equations and relationships are well-es-
At the same time, PPI’s Design and Engineering
tablished and can be used with the performance
Calculator helps engineers to increase their understand-
properties of the material to create a pipe system which
ing of PE pipe capabilities. Specifically, it helps the design
will provide years of durable and reliable service for the
engineer to perform multiple computations relating to
intended application.”
internal and external pressure ratings, pressure and
gravity water flow, water hammer, low pressure and high
Click on the links for more information:
pressure gas flow, as well as automating other assess-
❙ www.undergroundsolutions.com
❙ www.plasticpipe.org
❙ www.boreaid.com
ments for above and underground systems.
“As the significant economic advantages of trenchless
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Materials | technology
POLYPROPYLENE
LUBRICANTS
Clariant
soya-based
lubricant
Clariant has launched a new
lubricant based on renewable
resources for rigid PVC
applications. It is particularly
suited to compounds using
calcium/zinc and tin stabilisers and is claimed to offer
PP performs in sewer upgrade
extrusion equipment.
superior technical performance compared to traditional fatty acid derivatives
Czech pipe producer
main sewer lines, and DN150-
Elmo-Plast recently chose
DN200mm for the connections.
BorEco BA2000 polypropylene
The pipe material was based on
2000MPa, but uses no
chemically-modified wax
(PP) from Borealis to make
BorEco BA2000, which has high
mineral modifiers.
produced from soya beans and
solid-wall pipe for a recent
toughness, flexibility and
sewage network upgrade.
durability.
It has an e-modulus of
“I prefer it over mineralfilled PP grades,” said Ivo
Martinek, Elmo-Plast’s
and complex ester mixtures.
Licocare SBW11 TP is a
used in relatively low concentrations of 0.3 to 1.0 phr.
The network owners
The material allows pipe
wanted to reduce leakage
producers to make heavy-duty
owner. “Its high crystallinity
internal and external
and the risk of groundwater
pipes without mineral fillers,
provides a balanced combina-
lubricant, and has a number
pollution by replacing its
and without extra investment
tion of mechanical properties
of benefits: good release and
ageing concrete pipes.
in new production equipment.
and its high modulus enables
anti-sticking; high thermal
As a high molecular weight,
the production of heavy duty
stability; low volatility and
SN16 solid wall pipe DN315-
low melt flow block copolymer,
pipes without mineral fillers.”
good compatibility with PVC.
DN600mm was chosen for the
it runs easily on existing
❙ www.borealisgroup.com
❙ www.clariant.com
Elmo-Plast’s EM-Line PP
The additive works as an
HDPE
New grade puts the squeeze on tubes
Sabic has introduced a new
surface,” says Shyam Para-
specify the material for some
grade of HDPE, which it says
meswaran, technical market-
of its products.
can improve the aesthetic
ing engineer at Sabic. “We
“We are operating in a market
appearance and squeezability
have a stringent internal gel
where the quality of the
of collapsible tubes.
count control in place to
primary packaging plays a very
ensure material quality.”
important role,” said Hubert
combine well-balanced
Tubes extruded from the mate-
Polak, purchasing director of
mechanical properties with
rial are very flexible, making it
tubes at the company. “Using
ease of processing and
easier for users to squeeze out
HDPE F4520 makes a lot of
consistent quality. It is aimed
the contents. In addition, tubes
sense for us, and we expect it
at tubes for cosmetics,
can be squeezed repeatedly
to quickly have a positive effect
toothpastes and other
without puncturing. The
on our bottom line.”
products.
material also has very good
HDPE F4520 claims to
“Even very small imperfections in the polymer could
show up on the printed
www.pipeandprofile.com
resistance to stress cracking.
French packaging producer
Albéa has already begun to
Sabic says the European
market for collapsible tubes is
10bn units/year.
❙ www.sabic.com
September/October 2012 | PIPE & PROFILE EXTRUSION
37
technology | Machinery
twiin screw extrusion
profile extrusion
Milacron has expanded its
Parallel twin-screw extruder
line for smaller outputs
conical twin screw machine.
KM sells
extruders
to Ghana
line of TP Series parallel twin
products while still offering
Now, PVC, WPC and other
Interplast, a plastic pipe
screw extruders to include
minimal screw deflection to
materials can be processed
producer in Ghana in West
the TP75, a machine with a
optimise the homogeneity of
on this smaller parallel twin
Africa, has invested in more
75mm screw diameter.
the melt and maximise
screw,” said Mike Puhalla,
extrusion lines from
productivity.
general manager of global
KraussMaffei Berstorff.
The TP series now
The TP75 extrudes smaller
extrusion.
includes five models,
“Previously, smaller
with hourly through-
pipe and profile
puts up to 5000lbs
applications would
air- and oil-cooled barrels,
which a twin-strand process
(2272kg).
have required a
with optional gearbox oil
is used to produce PVC
quality monitoring and a high
panels. The panels, which
wear package with a
are up to 100mm wide, are
tungsten screw and barrel. A
used for wall and ceiling
longer 33:1 L/D option is also
panelling. The core compo-
available, as well as a Torque
nents of the systems are two
Master gearbox with internal
conical twin-screw KMD 63
oil cooling.
K/P extruders.
TP75 features include
❙ www.milacron.com/plastics
The latest order is for two
profile extrusion lines, on
Interplast first bought a
machine from KraussMaffei
Berstorff in 2011, when it
ordered a corrugated pipe
pipe corrugation
Corrugator set up online
Unicor, the German manufac-
Because of the risks of
extrusion system, a profile
extrusion line and a raw
material pelletising solution.
“With this profile produc-
ported via web interface by
tion system, we are confident
turer of corrugated pipe
visiting Iraq, Unicor could not
Unicor technicians – who
that technical difficulties can
extrusion lines, recently
send any technicians to the
followed the installation via a
be avoided because we are
supplied two new lines to Iraq
facility for start-up. Instead,
Remote Maintenance Unit
dealing with a partner who
– and started them by remote
three Iraqi staff members were
(RMU). This allowed handling
supplies us with all relevant
control via the internet.
intensely trained for two weeks
errors, or unexpected
components from a single
in Germany.
technical problems, to be
source,” said Arthur Huberts,
remedied within minutes.
CEO of Interplast.
The two UC 130 series
machines were bought by the
Iraqi Ministry of Water
Start-up was accomplished
on site by these staff, sup-
❙ www.unicor.com
Interplast, which was
Resources , which is responsi-
founded in 1970, exports to
ble for pipe production. The
more than 20 countries in
lines will be used to make PVC
Africa.
drainage pipes.
“We are proud that our
The corrugators produce
products are finding increas-
drainage pipes up to 130mm in
ing acceptance in Africa,” said
diameter that are subsequent-
Andreas Kessler, general
ly lined with a filter fleece. The
sales manager at KraussMaf-
fleece helps water absorption
fei Berstorff. “We will
and prevents the ingress of dirt
configure the system specially
particles, which often collect in
for Interplast to meet the
the drainage holes and block
market requirements.”
them.
❙ www.kraussmaffei.com
38
PIPE & PROFILE EXTRUSION | September/October 2012
www.pipeandprofile.com
This month’s free
brochure downloads
Simply click on the brochure cover or link to download a PDF of the full publication
Zumbach: in-line measurement
Battenfeld-Cincinnati: solEX
This eight-page brochure
from Zumbach covers the
company’s comprehensive
range of in-line
measurement and process
control systems for the
production of pipes, profiles
and tubing in plastics and
rubber.
Plastics – Rubber
This brochure from
Battenfeld-Cincinnati
provides full details on the
company’s solEX highperformance single-screw
extruder, which is designed
for HDPE and PP pipe
extrusion applications.
Complete Solutions for In-line Measurement
& Process Control
➤ Click here to download
➤ Click here to download
Amut: pipe extrusion lines
PlasMec TRM Turbomixers
This brochure from Amut
covers extrusion lines for
producing pipes in a variety
of materials and with
diameters up to 1,600 mm.
It includes extruders plus
cooling, calibration, haul-off
and cutting units.
This eight-page brochure
covers PlasMec’s TRM
Turbomixer, which can be
used for mixing PVC
dry-blends, producing
wood-plastics composites
(WPCs) or the hot/cold
dispersion of
masterbatches/additives.
Italiano - English
Linee di estrusione per
Tubi
Extrusion lines for
Pipes
➤ Click here to download
EXTRUSION
➤ Click here to download
Struktol: additives for plastics
SCITEQ
|
end closures
Sciteq: End closures
function
features
SCITEQ Air Frame stainless steel end closures
are produced for pipes and fittings to be used
for internal hydrostatic pressure testing. The
The SCITEQ end closures are produced in
stainless steel or acid resistant steel in various
weight of these end closures has been
dimensions from Ø315mm up to Ø1600mm.
reduced drastically compared to standard end
The SCITEQ Air Frame end closures are used for
closures with clamps in aluminium bronze.
relatively low pressures up to max. 40 bar in
The end closures comply with standards ISO
combination with temperatures between 20 to
9080, ISO 1167, ASTM D 1598, ASTM D 1599
95 degrees.
and equivalent.
highlights
up to max.
40 bar pressure
Struktol’s vast polymer additive experience is translated into the most
Quick Guides
resistance, durability and weight.
from O-ring to the internal bottom which ensures
that even on chamfered and oval PE-pipes, the
station is started while the airing-out screw is
diameter pipes compared to traditional large
open. When the sample is completely aired out,
diameter end closures, yet a robust construction
the test can be started. O-rings are produced from
has been maintained. The lower weight and
EDPM as for our other end closures.
incorporated.
The top end closure is delivered with a 1/4" male
connection and supplied with key operated bleed
valve. Other connections and bleed valves can be
high quality
material
supplied on request.
Struktol manufactures a complete line of additives that function individually
Struktol Company of America
Struktol Company of America is a member of the Schill & Seilacher family of companies, with representation in
over 100 countries around the world. A global organization with over a century of specialty chemical expertise,
Schill & Seilacher markets most of their polymer processing products under the brand name STRUKTOL® – a name
or in combination as adhesives, lubricants and surfactants, all accompanied
that has become synonymous with both quality and performance. Struktol manufactures chemicals for the plastics
by a wide range of benefits.
and rubber industry, foam inhibitors, polydispersions, silicone emulsions, products used in latex processing, and
POLYDIS®, a line of epoxy prepolymers and flame retardants.
The Struktol approach to the rubber and plastic additives business is by no means typical or ordinary. Chemistry
is at the heart of everything we do. Providing Intelligent Additive Solutions, Struktol products are designed to
Case Studies
meet the challenges and exacting demands of our customers. Our technical specialists, R&D chemists and
Improved Processing
compound laboratory are dedicated to creating innovative solutions for the ever-changing polymer industry –
A compounder of flame retarded polypropylene was
solutions that keep you ahead of your competition with increased productivity, better quality parts and lower
unable to efficiently mold their compound due to the high
overall cost. In addition to premium product performance, Struktol Customer Service initiatives have become
temperatures and pressures required during processing.
the industry benchmark.
The molding conditions caused problems with the flame
retardant system. By adding 1% of STRUKTOL® TR 251
the customer was able reduce the process temperature
by 20°C and reduce the pressures required to completely
fill the mold.
Improved Performance
A new feature is the possibility of supplying spare
low weight
intelligent solutions available anywhere. Each of our additives are tested and
retested to insure maximum product quality and performance consistency.
End closures are constructed with a specific depth
The weight is considerably lower for large
mounting. Further, grips for cranes have been
This brochure from Struktol
covers its wide range of
additives for thermoplastics,
including products for
superior viscosity control,
improved mixing and filler
dispersion, plus reduced
friction and plate out.
This brochure has details of
Sciteq’s Air Frame end
closures for the internal
hydrostatic pressure testing
of pipes and fittings. Made
from stainless steel, they
are much lighter than
aluminium bronze designs.
Get To Know Struktol
The construction has been selected for corrosion
end closure is tight while pressurising. The pressure
altered construction ensures easy handling when
easy handling
construction
A compounder of polycarbonate resin was able to
reduce the viscosity of his product by 25% using 1%
of STRUKTOL® TR 044W without sacrificing any clarity
parts for the clamps.
due to the additive. This viscosity reduction led to a
corresponding reduction in molded-in stress which
improved the mechanical performance of the material.
unique design
In addition the additive provided improved mold filling
Struktol Company of America
201 E. Steels Corners Road
P.O. Box 1649
Stow, OH 44224-0649
330-928-5188
800-327-8649
Fax: 330-928-0013
Email: customerservice@struktol.com
www.4struktol.com
version 02/2012
and release.
perfect sealing
Cost Reduction
A rigid PVC profile extruder was able to increase the
ideal for up
to Ø1600mm
addition level of regrind into his product by adding a
We wish to give our partners the tools to produce to the
highest standard, while helping them to produce as costeffectively as possible with Q.C. tools throughout the factory.
associated | equipment
costabilizing STRUKTOL® V Series product. The additive
maintained the heat stability of the compound resulting in
one set of air frame end closures model 1525
substantial cost per part savings due to the increased level
of regrind added. No performance reduction was seen.
Ø800mm internal diameter
|essential equipment
Many Struktol Intelligent Additive Solutions are the result of a partnering effort
between our customer and our sales and technical staff. If we don’t have the
pressure
stations
thermo
tanks
hoses
pc-sciteq
software
end closure
mounting
laboratory
saw
product that meets your needs you can count on us to develop something that
➤ Click here to download
exceeds your requirements.
SCITEQ — A Brand of Quality
TEB0047/2012
Intelligent Additive Solutions for
Today’s Thermoplastic Industry
➤ Click here to download
If you would like your brochure to be included on this page, please contact
Claire Bishop. claire@amimagazines.com. Tel: +44 (0)20 8686 8139
extruder of the month
Custom Profile
Head office:
Date founded:
Chairman:
Grand Rapids, Michigan, USA
1992
Sam Nicholas
Ownership:
Private (majority-owned by Blackford Capital)
Employees:
160
Profile:
Product lines:
Plant locations:
Company highlights:
Custom Profile is a manufacturer of plastic profiles for the appliance, furniture,
office and marine industries. It processes a variety of materials, including ABS, rigid
and flexible PVC, TPEs, HIPS and PP.
The company supplies a range of extruded profiles to companies including
appliance maker Whirlpool and office furniture maker Steelcase. It offers design
support, to help customers reduce costs and improve part functionality.
The company has two production facilities. Its main plant in Grand Rapids houses
13 extrusion lines, a far cry from the single-extruder operation of 20 years ago. In
2008, it became an international company by opening a facility in Juarez, Mexico.
The company was recently taken over by private equity firm Blackford Capital, which
is now the majority shareholder, though the existing management team remains
in place. With the new investment, the company intends to expand operations into
corrugated tubing (as well as into both injection and blow moulding), as well as
extending its reach to the telecoms, construction and automotive industries. The
firm says this may swell employee numbers by around 35 in the next three years.
To be considered for ‘Extruder of the Month’, contact the editor on lou@pipeandprofile.com
Forthcoming features
The next issues of Pipe and Profile Extrusion magazine will have special reports on the following topics:
November/December
Materials handling equipment
Wood-plastic composites technology
Cross-linked polyethylene (PEX)
PVC stabilisers
January/February 2013
Engineering plastics and composites
Pipe corrugators
Additives and colorants
Screenchangers and melt filtration
Editorial submissions should be sent to Lou Reade: lou@pipeandprofile.com
For information on advertising in these issues, please contact
Claire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139
Catch up on our recent
issues for FREE
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Pipe and Profile – July/Aug
The July/August issue of Pipe
and Profile Extrusion boasts
articles on a pipe maker’s
Olympics success, control
systems for increased
extruder efficiency,
developments in pipe fittings,
plus new test regimes.
➤ Click here to view
Pipe and Profile – May/June
The May/June edition of Pipe
and Profile Extrusion looks at
the latest developments in
processing WPCs and recycled
resins. It also reviews how
software is being used to
improve die performance and
profiles a water pipe
replacement project in
Casablanca.
➤ Click here to view
Compounding World – Sept
Compounding World’s
September issue is packed
with articles on developments
in pigments and colorants, the
North American masterbatch
industry, adding value with
mineral fillers, and how to
measure the weathering
resistance of plastics.
➤ Click here to view
Injection World – September
Injection World’s September
edition boasts features on
improving energy efficiency,
developments in optical
moulding and the latest
electronics applications, plus
it includes a preview of the
Fakuma 2012 exhibition.
➤ Click here to view
Compounding World – August
The August edition of
Compounding World takes a
detailed look at the latest
alternatives to phthalate
plasticisers, including biobased products. This issue also
looks at masterbatch carrier
resins and new developments
in reactive compounding.
➤ Click here to view
Film and Sheet – Aug/Sept
This issue of Film and Sheet
Extrusion focuses on the latest
developments in barrier
materials, the use of
measurement and control
systems to improve product
quality, plus recent innovations
in bioplastics.
➤ Click here to view
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dates for your diary
Global exhibition guide
2012
1-5 October
ColombiaPlast, Bogota, Colombia
www.colombiaplast.com
5-8 October
IndPlas 12, Kolkata, India
www.indplas.in
16-20 October
Fakuma, Freidrichshafen, Germany
www.fakuma-messe.de
24-27 October
VietnamPlas, Ho Chi Minh City, Vietnam
www.vietnamplas.com
14-15 November
Expoplast, Montreal, Canada
www.expoplast.org
29 Nov-2 Dec
Plast Eurasia, Istanbul, Turkey
www.plasteurasia.com
7-10 January
ArabPlast, Dubai, UAE
www.arabplast.info
29 Jan - 1 Feb
6-7 March
2013
Interplastica, Moscow, Russia
www.interplastica.de
Plastec South, Orlando, FL, USA
www.plastecsouth.com
12-15 March
Plastimagen, Mexico City, Mexico
www.plastimagen.com.mx
12-15 March
Pro-Plas Expo, Johannesburg, South Africa
www.proplasafrica.co.za
3-6 April
Tiprex, Bangkok, Thailand
www.tiprex.com
10-11 April
14-16 May
PlastTeknik, Malmo, Sweden
www.easyfairs.com
Plast-Ex, Toronto, Canada
www.plast-ex.org
20-23 May
Chinaplas, Guangzhou, China
www.chinaplasonline.com
20-24 May
Feiplastic 2013, Sao Paolo
www.feiplastic.com.br
18-20 June
Plastec East, Philadelphia, USA
www.plasteceast.com
Plastec Midwest, Chicago, USA
www.plastecmidwest.com
K2013, Düsseldorf, Germany
www.k-online.de
10-12 September
16-23 October
AMI conferences for pipe & profile extruders
9-10 October 2012 Polymer Foam, Newark, USA
23-25 October 2012 Polyolefin Additives, Cologne, Germany
18-20 February 2013 Pipeline Coating, Vienna, Austria
25-27 February 2013 Wood-Plastic Composites, Vienna, Austria
5-7 March 2013 Cables, Cologne, Germany
12-14 March 2013 PVC Formulation, Duesseldorf, Germany
9-11 April Pipes in Infrastructure, Düsseldorf, Germany
For information
on all these events
and other conferences on
film, sheet, pipe and
packaging applications, see
www.amiplastics.com
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