Extrusion Asia Edition 2-2025

43 EXTRUSION & RECYCLING ASIA 2/2025 为 20 至 25 年的系统以及低能耗。这意 味着投资能在很短时间内收回成本，” 安德烈亚斯·特克说道。 所描述的优势基于整个系统的工艺 工程设计，在该设计中，所有单独的 组件都完美协调，现代化且直观的控 制系统确保了可靠的输入和配置。在 大直径管材的挤出过程中，熔体温度 起着重要作用，因为这是导致意外下 垂的主要原因。安德烈亚斯·特克解释 道：:聚乙烯熔体的温度越低，其黏 度就越大，管材的下垂现象就越少。 下垂现象越少，管材的质量和壁厚分 布就越好。在挤出机本身方面，采用 solEX NG 挤出机，螺旋槽式机筒与 匹配的螺杆和带槽衬套的几何形状相 结合，能够在较低的螺杆转速下实现 较高的特定输出率，从而降低熔体温 度。与之前的挤出机相比，熔体温度 大约低 10°C。采用 OptiMelt 主动熔 体冷却系统，可进一步降低约 10°C 的 温度。这种强大的熔体冷却器安装在 挤出机和模具之间。此外，由巴顿菲 尔德 - 辛辛那提专利的两段式 VSI 管 模头，即螺旋芯棒分配器和筛篮的组 合，确保了管材内熔体的均匀分布， 从而保证了均匀冷却和极窄的壁厚分 布。得益于所有单个组件的精妙设 计，高品质的大直径管材能够以节能 的方式生产。所有下游设备均针对管 材尺寸范围广泛（最大可达 2.7 米）而 设计，能够以低能耗和低水耗运行， 这也为此做出了贡献。在真空和冷却 槽中，管材还可以沿圆周分段单独冷 却。这一选项还能进一步改善壁厚分 布并最大程度减少椭圆度。 battenfeld-cincinnati www.battenfeld-cincinnati.com Plastics Pipes & Products Co. (PPP) www.ppp-eg.com PIPE EXTRUSION – CASE STUDY “T he quality and precision of the large-diameter pipes we achieve on the new line from battenfeld-cincinnati is excellent,” says Ahmed El Mahalawy, owner of Plastic Pipes & Products Co. (PPP) in Cairo, praising the supplier of the new complete line. The Egyptian pipe manufacturer PPP has just completed a project with large- diameter pipes in Oman: high-quality pipes transport seawater to a desalination plant - an ideal application for plastic pipes, which score points here with their corrosion resistance. It is also an ideal application for large-diameter pipes, as large quantities of water can be transported e ciently in the shortest possible time. It is usually the material costs that enable the most money to be saved in the production of large-diameter pipes. “The main focus of our technology lies in the reduction of wall thickness toler- ances. Thanks to numerous optimiza- tions of the individual components of the system, we can now easily achieve values that correspond to half the DIN standard,” explains Andreas T rk, Sales Director at battenfeld-cincinnati. The dimensional accuracy and mini- mized wall thickness deviations alone mean that one line can save more than 1 million euros in rawmaterial costs per year compared to conventional lines and deviations. “Further advantages of our technology are the high output rates of two tons and more per hour, the lifespan of our systems, which are designed for 20 to 25 years, and their low energy consumption. This means that an investment pays for itself within a very short time,” says Andreas T rk. The bene ts described are based on the process engineering design of the overall system, in which all individual components are perfectly coordinated, and a modern and intuitive control sys- tem ensures reliable inputs and con g- urations. The melt temperature plays a major role in the extrusion of large- diameter pipes, as this is the main cause of unwanted sagging. Andreas T rk explains: “The lower the tempera- ture of the PE melt, the more viscous it is, and the less sagging occurs. The less sagging, the better the pipe qual- ity and wall thickness distribution.” In the extruder itself, a solEX NG, the combination of a spiral grooved bar- rel and matching screw and grooved bushing geometry ensures high spe- ci c output rates at low screw speeds and therefore low melt temperatures. Compared to previous extruders, the melt temperature is around 10 °C lower. A further temperature reduction of around 10 °C is achieved with the OptiMelt active melt cooling system. This powerful melt cooler is installed between the extruder and the mold. Furthermore, the two-stage VSI pipe head, a combination of spiral mandrel distributor and screen basket patented by battenfeld-cincinnati, guarantees uniform melt distribution in the pipe and thus ensures uniform cooling and extremely narrow wall thickness distri- butions. Thanks to the sophisticated concepts of all individual components, the high-quality large-diameter pipes can be produced in an energy-e cient manner. All downstream units, which are designed for a wide range of pipe not dimensions up to 2.7 m, can man- age with low energy and water con- sumption, contribute to this. In the vac- uum and cooling tanks, the pipe can also be cooled individually in sections around the circumference. This option can also further improve the wall thick- ness distribution and minimize ovality. battenfeld-cincinnati www.battenfeld-cincinnati.com Plastics Pipes & Products Co. (PPP) www.ppp-eg.com