helix PO pipe dies - Battenfeld Sverige AB

helix pipe dies
PO pipe dies to suit a wide range of applications
Dies made to ﬁt a great variety of customers’ needs
With its helix series, battenfeld-cincinnati offers its customers an extensive choice of custom-made PO pipe die models which can be adapted to meet a
great variety of demands. If, for example, a wide range of different materials are to be processed with high throughput rates, the 2-step distribution concept of VSI dies is the answer. By contrast, side-fed distributors or spider-type mandrel dies are the ideal equipment for processing materials such as EVOH
or PEX-b, where dwell time is a critical factor.
The custom-made dies include models such as modiﬁed VSI dies for 4-layer applications, 7-layer dies with 4 color stripes to produce PP pipes with ﬁberglass
and an oxygen barrier layer, but also multi-layer dies to process materials sensitive to dwell time, such as PEX-b. Complex multi-layer dies can be equipped
with different distribution concepts for the individual layers according to the special requirements in each case.
Our offer:
Optimal melt distribution concepts are available to suit all
areas of application and speciﬁcation proﬁles (VSI, spiral
mandrel distributors, side-fed distributors, spider-type mandrel dies or simple, compact radial distributors)
Your advantages:
High throughput
Precise wall thickness distribution
Long service life through short dwell time of the
melt in the die
Applications for pipe dies
Single-strand and twin-strand pipe extrusion
PE 63, PE 80, PE 100 for pressurized pipes with color stripes
for gas and water transport
Many different telecommunication pipes
Waste water pipes for non-pressurized applications
PP for hot water pipes
PP-R pressurized pipes for the chemical industry
PP-H drainage or sewage pipes, smooth or with ﬁller content
Pipes made of ABS, PEX, LDPE, LLDPE, PVDF, PPO, ABS/PC or
PA
Cable conduit pipes for power supply cables made of PP-O or
other pure polymers
Large-diameter pipe extrusion
(up to 2,500 mm)
PE 100 for pressurized water pipes
PE 80 or PE 100 non-pressurized drainage or sewage pipes in
wastewater treatment plants
Co-extrusion
Heating pipes with oxygen barrier layers
Smooth telecommunication pipes with silicone layer;
corrugated telecommunication pipes with/without silicone layer
PP sewage pipes with brown outer layers, white inner layers
and foamed middle layers, middle layers with ﬁller content or
made of reclaim materials
Sewage pipes made of black PE with a white inner layer
PE pipes with a scratch-resistant protective outer layer, a ﬂameretardant outer layer or a removable protective layer
PC or PC/ABS cable conduit pipes with an electro conductive
outer layer for electromagnetic shielding of data cables
PE pipes with a gasoline-resistant inner layer made of PA
Pipes made of different types of PE 100
Coated pipes
Composite pipes (e.g. aluminum-coated)
Steel pipes (adhesive layer or outer layer)
Corrugated pipes (third outer layer)
Other pipes (telecommunications, special underwater pipes)
VSI mono- and multi-layer dies
3
The unique VSI dies from battenfeld-cincinnati come with a 2-step distributor concept consisting of a spiral mandrel for preliminary distribution and a lattice basket
distributor for detail distribution. Particularly outstanding attributes are the excellent
homogenization, the wide processing window and the consistent, reliable product
quality for all pipe dimensions. VSI dies yield high output rates with relatively small
dimensions and are thus particularly well adapted to meeting numerous process technology requirements.
3-layer pipe with a brightly colored inner layer
for inspection purposes
VSI multi-layer dies are extremely maintenance-friendly thanks to their separate distribution systems for each layer, since the individual systems can be cleaned and serviced
separately. In co-extrusion processes, the inner and outer layers are united with the
middle layer as late as possible, so that several different materials, and in some cases
also different temperatures, can be used, as the distributors are not positioned on top
of each other, but staggered.
Their modular design makes it possible to set the dies either for three-layer applications
or for color stripes, and to adapt them to special customer speciﬁcations as well.
PE pipe for fuel lines with an inner layer made of polyamide
VSI-T – the VSI die with an EAC (Efﬁcient Air Cooling) tempering system
With EAC, battenfeld-cincinnati has set new benchmarks in pipe extrusion. With an air current ﬂowing against the extrusion direction, the pipe is now also
cooled from the inside. This raises extrusion performance.
EAC can be used for PE and PP pipes with diameters ranging from 63 to 2,500 mm in diameter and wall thicknesses of up to 150 mm. An existing VSI die
can be converted quickly and at low cost into a VSI-T, by replacement and/or modiﬁcation of just a few components. This is possible for all VSI mono-layer
and most VSI multi-layer dies (helix 250 VSI or higher). The proven VSI system with excellent melt distribution and homogenization and short dwell times is
preserved. Easy assembly and disassembly also remain unchanged.
Schematic depictions:
Central melt delivery
Decentral melt delivery
With the EAC system, the length of the cooling section can be shortened by at least 30% for pipe diameters of up to 500 mm, depending on the application,
and by at least 40% for pipe diameters above 500 mm. Alternatively, the throughput of the pipe extrusion line can be increased accordingly. The energy of
the heated exhaust air from internal pipe cooling can be reclaimed for purposes such as pre-heating granulates. The system also allows individual tempering
via the pipe’s circumference. This is achieved through segments placed around the circumference of the die.
VSI-T+
– the VSI pipe die with active intensive melt cooling
With the help of a melt cooling device precisely positioned between the spiral mandrel and lattice basket distributor elements, the melt temperature can be lowered gently and
extremely evenly. The main cooling medium is the ambient air, which, similar to internal pipe cooling, is sucked in through the melt cooling device in the die. The technical design
of VSI-T+ offers the following advantages:
Reduction of sagging in thick-walled pipes with high output rates
Reduction of pipe ovality
Further shortening of the required cooling section
All advantages offered by the high-performance, 2-step melt distribution concept of the VSI die. The modular
design with its retrofitting options remains unchanged.
Melt color change times are the same as for standard VSI dies
The active intensive melt cooling system can be operated independently of internal pipe cooling
The use of ambient air as the cooling medium minimizes operating costs and maintenance expenses
The contamination-free exhaust air discharged from the melt cooling device can be used unfiltered for granulate pre-heating or room heating
The internal pipe cooling and active intensive melt cooling systems can use the same exhaust air ventilator,
which reduces capital investment
Schematic depiction of a helix
630 VSI-T+ with central melt
delivery
Schematic ﬂow simulator depiction of the VSI-T+
active intensive melt cooling system
KryoS – efﬁciency newly deﬁned
KryoSys is a system which offers extreme efﬁciency and top performance in pipe extrusion. It can be used for all PE and PP mono-layer pipes with diameters ranging from 110
to 1,200 mm. Through air cooling of the inner pipe surface and additional melt cooling
inside the die, it is possible to reduce the energy consumption and shorten the cooling
section by 40 to 50%.
The KryoS concept offers decisive advantages in processing materials prone to sagging.
Even for large wall thicknesses (in relation to the pipe diameter to be produced), the
KryoS distribution concept has deﬁnite advantages due to its highly effective cooling
performance.
The KryoSys system also promotes better quality in the end product. Thanks to the
intensive cooling process, the drop in the OIT value is kept relatively small, and the
temperature distribution in the pipe wall is more even. The lower melt temperature
at the die outlet leads to reduced sagging. This is particularly important for high wall
thicknesses. Thanks to the integrated die outlet and mandrel heating system, a smooth,
glossy surface can be achieved in spite of the lower melt temperature.
KryoS pipe die
Coating dies
battenfeld-cincinnati also offers modular coating dies which can be adapted to a wide range of applications. Side-fed distributors are used for smaller pipes with thin walls. VSI
technology is used for pipes from 220 mm upwards. The latter is particularly recommended for large throughputs and large wall thicknesses. VSI technology operates with moderate pressures of, say, 250 bar and ensures low melt temperatures even at high throughput rates.
Schematic depiction of a coat 40 side-fed die
Depiction of a coat 700-2 VSI die for steel pipe coating (maximum throughput rate > 3,000 kg/h)
The advantages of battenfeld-cincinnati multi-layer coating dies are the modular design of every single layer and consequently optimized ﬂow geometries in every case. For the
outer layer (e.g. PEX-b) and the inner layer (e.g. adhesive layer; EVOH; adhesive layer), double side-fed distributors can be used. Elaborate centering of the individual layers can be
dispensed with thanks to the optimized distribution of the melt across the circumference.
Special VSI multi-layer dies
Our custom-built VSI multi-layer dies can be combined with either spiral mandrel or side-fed distributors according to the customer’s choice. Depending on the materials to be
processed, the optimal distribution concept is used in each case.
This yields the following advantages:
Top-quality distribution of the functional layers across the circumference
Mechanically and thermally homogeneous melt distribution
Minimal dwell time range for materials which start a process of cross-linking or thermal
degradation following melting (e.g. PEX-b and EVOH)
Long service life for the dies
Minimal expense for servicing and cleaning of the critical flow surfaces thanks to strategically positioned parting lines, without dismantling of the other components
Schematic depiction: helix 63-5 VSI with
compression unit for the adhesive layer
Schematic depiction: helix 1000-5 VSI
5-layer die
Fiberglass-reinforced PP-R
pipes with a layer thickness
distribution of 25-50-25
5-layer pipe with oxygen
barrier layer
helix PO pipe dies - output rates and technical data
Coating dies
Pipe die
Outer diameter
Warranty output*
coat 40 P
O.D. (8 x 0.2 to 40 x 2.0) mm
125 kg/h
coat 63 P
O.D. (16 x 0.2 to 80 x 2.5) mm
150 kg/h
coat 125 P
O.D. (25 x 0.3 to 125 x 2.5) mm
180 kg/h
coat 220 VSI
O.D. (75 x 0.5 to 220 x 7.0) mm
650 kg/h
coat 370 VSI
O.D. (100 x 0.5 to 370 x 7.0) mm
800 kg/h
coat 500 VSI
O.D. (160 x 0.5 to 500 x 7.0) mm
800 kg/h
coat 700 VSI
O.D. (220 x 0.5 to 700 x 7.0) mm
800 kg/h
coat 800 VSI
O.D. (350 x 0.5 to 800 x 7.0) mm
800 kg/h
KryoS pipe dies
Pipe die
Outer diameter
Warranty output*
helix 25-250 KryoS
O.D. (110 to 250) mm
1,200 kg/h
helix 25-400 KryoS
O.D. (110 to 400) mm
1,500 kg/h
helix 40-630 KryoS
O.D. (110 to 630) mm
1,800 kg/h
helix 63-1200 KryoS
O.D. (350 to 1,200) mm
2,500 kg/h
* All output rates quoted are based on the battenfeld-cincinnati material reference list for polyethylene. Output rates may vary, depending on materials processed as well as upstream and downstream equipment used.
VSI pipe dies
Choice of equipment options
Internal pipe cooling VSI-T
Pipe die
model
Range of application
Warranty
output*
central
delivery
decentral
delivery
active melt
cooling
VSI-T+
Co-ex–inner
layer
(5 to 15) %
Co-ex–outer
layer
(5 to 15) %
Color stripes
helix
20 VSI
O.D. (4 x 0.5 to 20 x 4.0) mm
max. 300 kg/h
–
–
–
X
XX
X
helix
32 VSI
O.D. (6 x 1.0 to 32 x 6.5) mm
max. 350 kg/h
–
–
–
X
XX
X
helix
63 VSI
O.D. (16 x 1.8 to 63 x 12.7) mm
max. 450 kg/h
–
–
–
X
XX
X
helix 125 VSI
O.D. (25 x 1.8 to 125 x 17.1) mm
max. 600 kg/h
O
O
O
X
XX
X
helix 160 VSI
O.D. (32 x 1.8 to 160 x 26.6) mm
max. 700 kg/h
O
O
O
X
X
X
helix 250 VSI
O.D. (50 x 1.8 to 250 x 34.2) mm
max. 1,200 kg/h
O
X
X
X
X
X
helix 400 VSI
O.D. (75 x 1.8 to 400 x 54.7) mm
max. 1,200 kg/h
O
X
X
X
X
X
helix 500 VSI
O.D. (90 x 3.5 to 500 x 45.4) mm
max. 1,200 kg/h
O
X
X
X
X
X
helix 630 VSI
O.D. (160 x 6.2 to 630 x 57.2) mm
max. 2,000 kg/h
X
–
X
X
X
X
helix 800 VSI
O.D. (250 x 4.9 to 800 x 58.8) mm
max. 2,000 kg/h
X
–
X
X
X
X
helix 1000 VSI
O.D. (250 x 4.9 to 1,000 x 59.3) mm
max. 2,000 kg/h
X
–
X
X
X
X
helix 1200 VSI
O.D. (280 x 10.7 to 1,200 x 120.0) mm
max. 2,000 kg/h
X
–
X
X
X
X
helix 1600 VSI
O.D. (630 x 12.3 to 1,600 x 120.0) mm
max. 3,000 kg/h
X
–
X
O
O
X
helix 2000 VSI
O.D. (630 x 12.3 to 2,000 x 120.0) mm
max. 3,000 kg/h
X
–
X
–
–
X
helix 2500 VSI
O.D. (1,000 x 24.5 to 2,500 x 120.0) mm
max. 3,000 kg/h
X
–
X
–
–
X
Symbol legend:
–
= not included in the supply schedule
O
= available as an option
X
XX
= available
= available for up to 4 co-ex outer layers
battenfeld-cincinnati
Austria GmbH
battenfeld-cincinnati
Germany GmbH
battenfeld-cincinnati (Foshan)
Extrusion Systems Ltd.
battenfeld-cincinnati
USA
Laxenburger Str. 246
1230 Wien
Königstraße 53
32547 Bad Oeynhausen
2 Jinxiang Road, Daliang, Shunde
Foshan, Guangdong
823 S. By-Pass, P.O. Box 832
McPherson, KS 67460, USA
P +43 (1) 61006-0
F +43 (1) 61006-8
P +49 (5731) 242-0
F +49 (5731) 27124
P +86 (757) 2238 0110
F +86 (757) 2221 1801 / 2238 0195
P +1 620 241-6843
F +1 620 241-0207
[email protected]
[email protected]
[email protected]
[email protected]
www.battenfeld-cincinnati.com
www.battenfeld-cincinnati.com
www.battenfeld-cincinnati.com/china
www.battenfeld-cincinnati.com/usa
Edition 3 / 09-2013
Subject to technical alterations.

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