Efficient extrusion technology for best production results

In Russia there is a demand for plastic pipe in building and infrastructure projects. This includes small pipes for domestic installations, such as aluminum composite pipes for floor heating, as well as large diameter pipes for water and gas transport with diameters of up to 1.6 m (PVC) and up to 2.6 m (PO). battenfeld-cincinnati offers complete lines for pipes of all sizes and materials. Extruders are now equipped with the new BCtouch UX control system that offers an intuitive operating concept and fulfills the requirements for efficient production planning, preventive maintenance and Industry 4.0 applications.

Complete extrusion lines for high performance, energy and material savings in pipe and profile extrusion

For large diameter PO pipe extrusion (up to 2.6 m), the new solEX NG single screw series offers outputs up to 2,500 kg/h. The newly designed, groundbreaking processing unit enables up to 10°C lower melt temperatures, an optimized, constant pressure build-up and therefore reduces maintenance costs and lowers energy costs by up to 15%. In production lines for both mono- and multi-layer PO pipes, battenfeld-cincinnati’s proven helix II VSI pipe heads ensure best distribution of the melt with their two-step distribution concept. The combination of solEX NG and helix II is especially well suited for large diameter PO pipe extrusion. For this application, battenfeld-cincinnati offers complete lines for diameters up to 2.6 m.

The new conEX NG conical twin screw extruder is ideal for the production of PVC pipe and profile. It features a longer pre-heating zone and an optimized screw design for higher outputs (up to 250 kg/h for profile and up to 450 kg/h for pipe). The new geometry concept minimizes wear, and a great variety of material blends can be processed with just one screw configuration. The conEX NG is also an excellent choice for co-extrusion, e.g. in window profile production. Several space-saver and pedestal designs can be optimally adapted to the main extruder.

For large diameter PVC pipes that are used for water management, the parallel twinEX twin screw extruder range is also ideally suited. Their 34D processing unit serves to expand the processing window and improve the quality of the melt, while optimized screw concepts ensure high outputs of up to 2,500 kg/h for pipe and up to 600 kg/h for profile. Complete PVC pipe production lines include spider pipe tooling designed for processing a great variety of material blends. The special geometry ensures even and accurate wall thickness distribution and low pressure build-up.

Increased flexibility and cost savings with the fast dimension change (FDC) system

The FDC system allows producers of medium-sized PO pipes to change external diameters and pipe wall thicknesses during production, as well as to effect color changes much faster, thus saving downtimes and material. Dimension changes work fully automatically at the push of a button across a wide range of diameters. Complete systems are available up to diameters of 630 mm, which is currently unique in the market.

Efficient high-speed extrusion of thermoforming sheet

Another sector that is becoming more and more important in Russia is the food packaging industry. Barrier sheet has up to 9 layers and prevents oxygen from affecting food, increasing its shelf-life.

High-grade packaging and fruit containers are often made of PET due to its high transparency. For this application, battenfeld-cincinnati offers the STARextruder series. It has been designed to meet the requirements of PET processing, by combining a single screw with a planetary roller section for highly efficient degassing of the melt. They are ideal for medium output ranges up to 1,500 kg/h. For co-extrusion applications, battenfeld-cincinnati offers its own feedblock and a variety of roll stacks adapted to customers’ needs.

For efficient, high-performance extrusion of mono- and multi-layer thermoforming sheet, the high-speed extruder series and the Multi-Touch roll stacks are the ideal combination.
High-speed extruders enable energy savings of 15-20%, as well as improved melt quality thanks to a reduction in residence time. Extremely high outputs of up to 1,500 kg/h for PP, up to 1,750 kg/h for PS, and up to 1,200 kg/h for pre-dried PET can be achieved.

The Multi-Touch roll stack series has an innovative multi-nip process that produces stress-free sheet and saves material, thanks to thickness tolerances of only +/- 1%, even at high line speeds and outputs of up to 3,000 kg/h for PP and up to 3,300 kg/h for PET.

battenfeld-cincinnati also offers extrusion lines for ABS/PS and HDPE/PP mono- and co-extruded sheet in widths up to 1,900 mm and thicknesses between 0.5 and 10 mm.

battenfeld-cincinnati is a leading producer of energy-efficient, high-performance extruders and complete extrusion lines according to customers’ specific requirements. It offers a variety of equipment for many different applications in the areas of pipe, profile, sheet, thermoforming sheet and pelletizing. Customers are supported by production facilities in Germany, Austria, China and the USA, as well as an extensive worldwide sales and service network.

Source: battenfeld-cincinnati