Pipe Extrusion

PIPE extrusion plants PLASTICS PROCESSING TECHNOLOGY

EXTRUSION TECHNOLOGY

PIPE EXTRUSION PLANTS

AMERICAN MAPLAN CORPORATION


TABLE OF CONTENTS Page Automation

4 - 5

Single screw extruder

6

Twin screw extrude extruderr

7

PO dies PVC dies

8 - 9 10 - 11

Vacuum calibrators and spray cooling baths

12

Calibration sleeves

13

Haul-off units

14 - 15

Cutting devices

16 - 17

Belling systems

18

Twin strand extrusi extrusion on

19

Steel pipe jacketing

20

2



AUTOMATED MACHINE LINES

Faster, higher output, more economical – these are

The functions of all plant elements are harmonized

the market requirements placed on pipe extrusion

and equipped with efficiently operating automation

plants. These These coincide w ithout exception in plant

systems. We supply technology meeting the highest

development. This is the primary reason why Ameri-

requirements so that you can produce the best pos-

can Maplan is the market leader in pipe extrusion

sible quality.

equipment production. Our customers benefit from our core competency in the manufacture of complete extrusion lines and also from the experience gained in the development of intelligent automation solutions.

3



AUTOMATION

OUR CONTROL SYSTEMS

OUR CONTROL SYSTEMS

BMC offers:

American Maplan tele-maintenance provides the

Central and efficient operation

fastest support of operating personnel worldwide in

Reproducible Reproducibl e production

diagnosis, optimization of process parameters and

Documented quality

malfunction remedy. Production downtime is minimi-

Automation of the entire machine line

zed because the knowledge of our qualified personnel is directly available on site.

Line 1

Line 2

...n

4



CONTROL SYSTEM Well arranged and simple: the easily configurable control surface in combination with the stepped automation concept ensures efficient operation in all areas of pipe extrusion. The integration of system extensions, such as dosing systems, co-extruders, co-extruders, melt pumps and an intelligent sensor system in the central control system is pos-

User friendly operation

sible. The The control system is complemented by its network integration and tele-maintenance capabilities.

STEP II IN AUTOMATION The efficiency of the system can be increased by the integration of an intelligent gravimetric sensor system. One main and up to five secondary components per extruder are possible. In addition, the weight per metre of the product is kept constant at all times by a stabilized mass throughput and the slaved take-off speed.

STEP III – IV IN AUTOMATION The integration of ultra-sonic measuring chambers chambers allows further advantages in pipe production, as

Dosing station

product monitoring and documentation are notably improved and manual centering is simplified. Optionally, thermal centering tools can be implemented in the automation process. Last but not least, the possibility of minimum wall thickness variation generates a further reduction in material consumption.

Weigher

Wall thickness display

Ultra-sonic measurement

5



SINGLE SCREW EXTRUDER

HIGH PERFORMANCE EXTRUDER

GROOVED FEEDBUSH

Be it maximum output in special application fields or

For the extrusion of polyolefin pipe in particular, the

extreme versatility – the single screw extrude extruders rs from

American Maplan extruders are equipped with a

American Maplan are chosen because of their indus-

grooved feedbush. In combination with a barrier screw,

try-leading technology and the easy integration with

this means that particularly plastification outputs are

all extrusion components.

achieved at an excellent homogeneity of the melt.

Single screw extruder

For speciﬁcation, please refer to the technical report.

Type

1-45-30B

1-60-30B

1-75-30B

1-90-30B

1-120-30B

1-150-30B

1-220-30B

Output [kg/h]

220 - 240

370 - 400

540 - 580

750 - 800

1100 - 1200

1500 - 1700

2000 - 2300

Performance Performa nce information depending on pipe dimensions and material type.

6



TWIN SCREW EXTRUDER

28D PROCESSING UNIT

COMPETENCY

American Maplan has set new standards in PVC

Highlights of the American Maplan twin-screw extruders:

extrusion by the development of their processing

Compact design

units. The The processing technology is distinguished by

Screw temperature control via sealed water or active oil

its improved product quality, higher output and an

Heating with ceramic heating bands

enormous processing range.

Barrel cooling by means of air blowers or tempered fluid Stuffer for screw rotational speed reduction Screw rotational speed

Single screw extruder Type Output [kg/h]

For speciﬁcation, please refer to the technical report

CON 40

BEX 54

DSK 62

TS 92

BEX 92

TS 10 0/2

TS 110

TS 135

BX 168

5 - 60

20 - 130

30 - 300

140 - 550

150 - 350

160 - 650

250 - 800

450 - 1650

110 - 2300

Performance Performa nce information depending on pipe dimensions and material type

7



Dies for POLYOLEFIN PIPE EXTRUSION Whether for the transport of water or gas, or for any industrial use, multi-layer polyolefin pipes are defined by their flexibility and variability. In this field, American Maplan offers a wide range of dies for the selection of the right solution for every requirement.

VSI SCREEN DIES Lattice basket dies are used for the extrusion of HDPE, LDPE, L DPE, HMW-PE, HMW- PE, PP, ABS and an d PS. Advantages: Low melt pressure and temperature, even at high throughput Good homogenization by the two-stage distribution concept, consisting of a spiral thread and a compact lattice basket Consistent product quality at all pipe dimensions Large processing range with multiple material viscosities Short purge times by designing short dwell time into the die

Lattice basket dies Type Pipe diameter [mm] Max. throughput [kg/h]

Type Pipe diameter [mm] Max. throughput [kg/h]


PO 32/350

PO 63/40 0

PO 125/450

PO 25/70 0

10 - 32

16 - 63

25 - 125

50 - 250

350

400

450

700

PO 450/80 0 PO 630/90 0 PO 80 0/10 0 0 PO P O 10 0 0/ 0/10 00 00 PO 120 0/ 0/120 0 PO 140 0/ 0/120 0 P O 140 0/ 0/130 0 90 - 450

200 - 630

315 - 800

450 - 1000

630 - 1200

710 - 1400

710 - 1600

800

1000

1200

1200

1200

1200

1200

8



MULTI-LAYER DIES Pipe properties can be optimized in a targeted manner by c o-extruding several materials. The The correct die depends on the individual application. American Maplan develops and produces dies for the widest range of co-extrusion applications – optimally matched to the specific product requirements.

RADIAL DISTRIBUTOR WITH SCREEN PLATE This low-cost die is particularly characterised by its robust and compact construction design. The additional screen plate improves the distribution and homogenization of the melt similar to the lattice basket by providing a double deflection. In conjunction with the proven lattice basket in the main layer, a wide application range is guaranteed at all times.

LATTICE BASKET DIE WITH THREE LAYER SPIRAL MANDREL DIE While the lattice basket with its known advantages is used for the thicker center layer, frequently consisting of a low-cost material, the spiral mandrel die finds its application to meet the high requirements of the surface quality for thin inner and outer layers.

FIVE LAYER SPIRAL MANDREL DIE Meets the requirements for the production of PO hot water pipes. Advantages: Ideal homogeneity and wall thickness distribution of all 5 layers Highly compact tool design Relatively short flow paths from the extruder to the die exit

9



Dies for PVC PIPE EXTRUSION

For sensitive PVC materials, American Maplan

SPIDER DIES

counts on flow-optimized single and double spider dies. Both die types guarantee uniform

For PVC processing, the geomet-

melt distribution throughout the entire pipe

ric die design offers the following

circumference in an ideal manner.

advantages: Very good flow properties throughout the entire flow channel

Ideal dwell time spectrum with targeted temperature control of the sensitive material

Spider dies


Type

RK 1

RK 1.5

RK 2

RK 3

RK 4

RK 5

RK 5.5

Pipe diameter [mm]

16 - 50

16 - 75

40 - 90

75 - 160

140 - 280

225 - 355

315 - 500

175

575

625

775

1075

1350

1800

Max. throughput [kg/h]

RK 6

RK 6.5

355 - 630 400 - 800 1800

1800

10



FOAM CORE PIPE ADAPTER The sophisticated concept of the co-extrusion adapter permits the production of weight-reduced foam core pipe as well as pipe with a compact center layer made of low-cost reclaim. The pipe is shaped as usual by a conventional PVC spider die. The special design of the adapter permits optional operation with one or two co-extruders for the compact inner and outer layer.

DOUBLE SPIDER DIE The PVC double spider dies are a further development offering the following advantages: Low pressure build-up Higher volume within the die Larger dimensional range Higher throughputs No continuous spider die marks Better mechanical properties

Double spider dies Type Pipe diameter [mm] Max. throughput [kg/h]


RD 0.5- 4

RD 1-7

RD 2-10

RD 6-18

RD 12- 27

RD 15- 36

RD 24- 48

16 - 110

15 - 175

50 - 280

150 - 450

300 - 710

355 - 1000

630 - 1300

450

1000

1200

1800

2500

2500

2500

11



VACUUM CALIBRATORS and SPRAY COOLING BATHS

SINGLE/DOUBLE CHAMBER

SPRAY COOLING BATHS

VACUUM CALIBRATORS Performance features: A new generation of vacuum calibrators with

Circulation pump

desirable features:

Filter with manual return

Patented fast vacuum regulation

via bypass

Precise temperature control

Temperature control via thermo-

Flow optimized pipework made of

stat valve in the water supply

stainless materials

Central water drain

Vacuum limiter

Temperature display

Cold water temperature control

Water collector at the intake

Circulation and vacuum pumps

and outlet

Double filter unit

Vacuum calibrators and spray cooling baths Type

Pipe diameter [mm]

Type

V 63 VA - 6m V2-63 VA - 6m V2-63 VA - 9m CB 63 VA - 6m



V 250 VA - 6m V2-250 VA VA - 6m V2-250 VA VA - 9m CB 250 VA - 6m

10 - 63

20 - 125

20 - 160

40 - 250

V 630 VA - 6m

V 800 VA - 6m V2-800 VA - 9m CB 800 VA - 6m

V 1000 VA - 6m V2-1000 VA - 9m CB 1000 VA - 4m

V 1200 VA - 6m V2-1200 VA VA - 9m CB 1200 VA - 4m

200 / 400 - 800

200 / 450 - 1000

315 / 630 - 1200

V2-630 VA - 9m CB 630 VA - 6m Pipe diameter [mm]


110 / 140 - 630

V 500 VA - 6m V2-500 VA VA - 9m CB 500 VA - 6m


90 / 140 - 500

50 - 400

V 1400 VA - 6m V2-1600 VA - 12m V2-1400 VA - 9m CB 1400 VA - 4m CB 1600 VA - 6m 315 / 60 - 1400

710 - 1600

12



The right CALIBRATION SLEEVE for every application

American Maplan supplies calibration inserts for all technical plastic materials. Advantages: Excellent heat conductance High wear resistance Good glide properties High production output

Calibration sleeves Type Material Diameter [mm] C oo ooling principle


I

II

IV

V

VI

PC, ABS, PS

H D PE

PO, PB, PA

PP, PE-MD/LD

H D PE

10 - 1000

32 - 110

32

32

110 - 1600

Intens iv ive c oo ooling

Intensi ve ve cooling , adjustable water ring

Disc calibration with pre-chamber; optional: spray ring

Intensive cooling, adjustable glide cooling

Dry inlet and spray cooling

13



HAUL-OFF UNITS

The suitable haul-off for every requirement:

MULTI-MOTOR TECHNOLOGY

American Maplan offers: Belt haul-off units for small PO pipe at high production speed

As far as drive systems are con-

Caterpillar haul-off units predominantly for

cerned, American Maplan counts on

pipe of a small to medium diameter

an ultra-modern technology consist-

Multiple caterpillar haul-off units for

ing of a digital controller and a sepa-

thin-walled and larger pipe

rate AC servo drive at each caterpillar. This means the haul-off speeds can be precisely synchronized. The The system is characterized by the following performance criteria: A mechanical power distribution is no longer required Improved efficiency Optimization of production

Multiple caterpillar haul-off units


R 125/3+1 VE

R 125/4

10 - 63

20 - 125

20 - 160

20 - 160

Type

R 50 0/4

R 50 0/6

R 630/6

R 630/8

Pipe diameter [mm]

50 - 500

75 - 500

75 - 630

75 - 630

Type Pipe diameter [mm]

R 125/3 VE R 160/3+1 VE R 160/3 VE

R 250/4

R0 250/6

R 40 0/4 E

R 40 0/6 E

20 - 250

50 - 250

48 - 400

75 - 400

R 80 0/6

R 10 0 0/8

R 140 0/10

R 160 0/10

R 20 0 0/12

160 - 800

250 - 1000

500 - 1400

300 - 1600

500 - 2000

32 - 160

14



DOUBLE CATERPILLAR AND BEL BELT T HAUL-OFF UNITS Precise synchronization by AC servo drives Parallel guidance of the oscillating top belt/caterpillar at the front side Pneumatic contact pressure by dual cylinders Belt haul-off units for high extrusion speeds of >25 m/min

MULTIPLE CATERPILLAR HAUL-OFF UNITS The multiple caterpillar haul-off units are suitable for almost all pipe diameters. Advantages: Wide segments Long contact length High haul-off forces

Belt haul-off units


Type

P 50 BVE

P 10 0 BVE

P 160 BVE

10 - 40

10 - 63

10 - 110

Pipe diameter [mm]

Twin caterpillar haul-offs Type Pipe diameter [mm]


R 50 SE

R 10 0 SE

R 160 SE

R 250 SE

25 - 63

25 - 90

25 - 125

32 - 250

15



CUTTING DEVICES

American Maplan offers cutting devices that

PO pipes, chip

meet all requirements. Our range encom-

removing cut-

passes upstroke saws, planetary cutters and

ting with a spe-

automatic pipe cutters.

cial saw blade Depending on

PLANETARY SAWS

the design, the saw carriage

Performance features for circulating saws and

is equipped

cutters:

with a pneu-

PVC pipes, chip removing cutting and

matic drive or a

bevelling on one or both sides

servo drive

PVC foam core pipes, chip removing bevelling first, followed by cutting without chips

Planetary saws Type Pipe diameter [mm]


STU 125

STU 160

STU 250

STU 50 0

STU 80 0

SU 10 0 0

SU 140 0

SU 160 0

25 - 63

16 - 160

40 - 250

75 - 500

160 - 800

250 - 1000

300 - 1400

300 - 1600

16



PLANETARY CUTTING DEVICE Performance features for PE and PP pipe cutting without chips: Pneumatic saw carriage advance Basic equipment for jaw clamping Guide conveyor in the infeed as a roller table, in the outfeed as a V channel, central, mechanical height adjustment Integrated PLC control system/operation

AUTOMATIC AUTOMA TIC PIPE CUTTER Fast conversion to a different pipe dimension and cutting techniques Minimal noise cutting process Cutting of PO pipe without chips Chip removing cutting and bevelling of PVC pipe

Cutting without chips and chip removing bevelling of PO pipe

Planetary cutting device


Type

TU 125

TU 160

TU 250

TU 50 0

TU 80 0

0 - 125

16 - 160

40 - 250

90 - 500

160 - 800

Pipe diameter [mm]

Automatic pipe cutter Type Pipe diameter [mm]


RTA 63

RTA 125

RTA 250

RTA 50 0

RTA 80 0

RTA 120 0

10 - 63

20 - 125

50 - 250

90 - 500

250 - 800

500 - 1200

UPSTROKE SAWS Pneumatic saw blade advances vertically upward Efficient chip extraction Saw hood with integrated clamping above the saw table

Upstroke saws Type Pipe diameter [mm]


SPR 63 P

SPR 63 E

63

63

SPR 125 P SPR 125 E SPR 125 H SP SPR R 250 250 P SP SPR R 250 250 E 125

125

125

250

250

17



BELLING MACHINES

An American Maplan construction series of

PVC pipe

belling machines covers all fields of applica-

9 machine types from

tion. Heating and forming methods adapted

10 to 1200 mm

to the most varied pipe materials not only

PE and PP pipe

guarantee a consistently high product quality,

5 machine types from

but also an optimal output matched to each

32 to 630 mm

extruder.. Pipe stackers and bundling devices extruder complete the range with regard to economical and highly productive extrusion.

RIEBER sealing ring 5 machine types from 50 to 1200 mm

NEW HEATING SYSTEM AWI PLUS (Pat. pend.) Substantial reduction of the heating time No thermal deterioration of the pipe Absolutely uniform pre-heating Operating temperature reached within Rieber belling unit

one second High energy saving

Belling machines Type Pipe diameter [mm]


KK 70 70/2 A

KM-D 12 125 A

KM-D 16 160 A

KM-D 25 250 A

KM-D 50 50 0 A

KM-D 65 650 A

KM-D 80 80 0 A

KM-D 10 00 00 A

KK-D 12 120 0 A

10 - 75

25 - 125

50 - 160

50 - 250

110 - 500

180 - 630

180 - 800

280 - 1000

400 - 1200

18



TWIN STRAND EXTRUSION

Twin strand pipe extrusion is to be recommended where high throughputs are to be achieved with small pipe diameters. Advantages: Independent speed control per strand Possibility to produce diff different erent diameters at the same time Twin strand lines with two independently controlled downstream units

19



STEEL PIPE JACKETING

Polyethylene is best suited to protect steel

PIPE WRAPPING

pipe from corrosion. American Maplan offers two extrusion methods for PE jacketing:

For pipe wrapping, a first extruder

Pipe jacketing for smaller pipe diameters

extrudes the coupling agent as a

Pipe wrapping is used for larger

film layer, while a second extruder

pipe diameters

applies the multi-layer PE wrap. A homogeneous compound material

PIPE JACKETING

is achieved by the high pressure applied as the wrapping layers are

For pipe jacketing, the pretreated pipe is con-

placed on the pipe surface.

tinuously guided through a cross extrusion die while the melt is applied to the pipe by vacuum.

20

e g n a h c o t t c e j b u S

THE POWER to SUCCEED


PO Box 832 McPherson, KS 67460 Phone 620 241 6843 Fax 620 241 0207 E-mail: [email protected] Internet: www.maplan.com

y n a m r e G n i d e t n i r P . y a K . 3 0 2 4 , W S F , E , T R , 4 0 / 9 0 X E B

Pipe Extrusion

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