Pipe & Profile March 2015
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ISSN 2053-7182<br />
<strong>March</strong> <strong>2015</strong><br />
NPE <strong>2015</strong>: TAKING OFF IN FLORIDA<br />
CONTINUOUS & BATCH MIXERS FOR PVC<br />
LATEST DEVELOPMENTS IN POLYOLEFINS<br />
UPDATE: SCREW & BARREL TECHNOLOGY
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contents<br />
05 Industry news<br />
PAGE 5<br />
German plastics processing on the rise; Uponor invests $18m to expand PEX in North<br />
America; Rapid returns to Sweden; ADS expands in Canada; Fullerenes for cable<br />
protection<br />
11 Reaching a century: polyolefin developments<br />
Separate testing procedures have found that polyolefin pipes are likely to last beyond<br />
PAGE 11<br />
100 years – in both pressure and non-pressure applications. Lou Reade reports<br />
19 Turning a profit: screws and barrels<br />
New concepts in screws and barrels help to extend machine lifetime and boost<br />
throughput<br />
PAGE 23<br />
23 Creating a stir with the latest mixers<br />
Pat Toensmeier reports on recent developments in continuous and batch mixers,<br />
including improvements in rotor and machine designs<br />
31 NPE: lifting off in Florida<br />
PAGE 31<br />
NPE <strong>2015</strong> kicks of this month. We look at why it is shaping up to be huge success, and<br />
preview a selection of new products that will be on show<br />
41 Technology: Materials<br />
42 Technology: Machinery<br />
PAGE 41<br />
46 Extruder of the month: Tubi<br />
48 Dates for your diary<br />
coming next issue<br />
❙ Control & Instrumentation ❙ Laboratory extruders ❙ Computer modelling software ❙ Plast preview issue<br />
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www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 3
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news<br />
IMCD and<br />
Dow extend<br />
agreement<br />
GKV: German plastics<br />
processing rises in 2014<br />
IMCD is to distribute Dow’s<br />
German plastics processors<br />
added significant jobs in<br />
Paraloid impact modifiers<br />
increased their turnover again<br />
Germany in 2014,” said<br />
and Surecel processing aids<br />
last year, showing accelerated<br />
Westerheide. “Our industry<br />
in Germany, Austria and<br />
growth compared to 2013 –<br />
now has more than 311,000<br />
Switzerland from 1 <strong>March</strong>,<br />
and faster growth than the<br />
employees, which continues<br />
and in the UK from 1 June.<br />
economy in general.<br />
the upward trend of recent<br />
The new agreement is an<br />
Total sales in 2014 in-<br />
years.”<br />
extension of a long-estab-<br />
creased by 2.6% to reach<br />
He was confident for the<br />
lished partnership between<br />
E59bn (US$67bn) according to<br />
coming year, based on the<br />
the two companies. It also<br />
Dirk Westerheide, president of<br />
latest survey of GKV members:<br />
complements the recent<br />
trade association GKV, which<br />
63% of respondents expected<br />
appointment of IMCD as<br />
produced the figures.<br />
increased turnover this year,<br />
Dow’s pan-European<br />
“This achieved a new<br />
while 30% expected no change<br />
distributor for its Tyrin<br />
record,” he said.<br />
and 7% predicted reduced<br />
chlorinated PE range.<br />
Domestic sales were up<br />
Westerheide: “Sales in 2014<br />
turnover.<br />
Paraloid, Tyrin and<br />
1.9% to E37.8bn (US$43bn),<br />
achieved a new record”<br />
However, he said that<br />
Surecel additives are used<br />
while exports grew 3.4% to<br />
Germany’s high energy costs<br />
as impact modifiers and<br />
E21.2bn (US$24bn). At the<br />
the sector’s 2,866 companies<br />
– which continue to rise<br />
processing aids in a wide<br />
same time, the amount of<br />
also grew by 2.6% in the same<br />
because of the expansion of<br />
range of PVC compounds.<br />
material processed, at 13.6m<br />
period, he added.<br />
renewable energy – could<br />
❙ www.imcdgroup.com<br />
❙ www.dow.com/additives<br />
tonnes, rose by 3%. The rise in<br />
the number of employees in<br />
“The mainly medium-sized<br />
companies in our industry<br />
derail this growth in future.<br />
❙ www.gkv.de<br />
Rapid Granulator returns to Swedish hands<br />
Swedish size reduction<br />
not be impacted by the sale.<br />
processing tyres, cables,<br />
product line, so the Rapid<br />
company Rapid Granulator has<br />
Eldan Recycling is a global<br />
aluminium and various other<br />
acquisition is complementary<br />
changed hands – switching<br />
supplier of recycling equip-<br />
scrap materials. It does not<br />
to its activities.<br />
from US-based Ipeg to<br />
ment and systems for<br />
have its own granulator<br />
Toni Reftman, managing<br />
Sweden’s Lifco.<br />
director of Lifco subsidiary<br />
Rapid is based in Bredaryd,<br />
Eldan Recycling, will assume<br />
Sweden, while its North<br />
responsibility for the Rapid<br />
American operations are in<br />
business.<br />
Cranberry Township, USA. All<br />
“This acquisition will bring<br />
Rapid employees are expected<br />
together two companies that<br />
to remain with the company,<br />
are able to offer a fully<br />
other than CEO Kirk Winstead,<br />
complementary portfolio –<br />
who will remain within Ipeg.<br />
making us in effect the world’s<br />
Republic Machine, previously a<br />
largest recycling machine<br />
division of Rapid Granulator<br />
company in our field,” said<br />
Inc, is now a subsidiary of Ipeg<br />
Reftman.<br />
and will remain within the<br />
❙ www.rapidgranulator.com<br />
group. Other Ipeg companies<br />
– such as ancillary supplier<br />
Eldan’s Toni Reftman will also<br />
Conair and shredder manufac-<br />
assume responsibility for the<br />
turer Republic Machine – will<br />
Rapid business<br />
www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 5
news<br />
Uponor invests $18m to<br />
expand PEX facility in US<br />
Eurocell to<br />
float in<br />
London<br />
Uponor is to expand produc-<br />
footprint will amount to more<br />
this expansion will ensure we<br />
Eurocell, a UK manufac-<br />
tion in the US by investing in<br />
than 650,000 sq ft in the area<br />
match forecast growth and<br />
turer and distributor of PVC<br />
its facility in Apple Valley,<br />
– on 50 acres of total property.<br />
demand for our PEX systems.”<br />
window, door and roof<br />
Minnesota.<br />
The expansion is needed in<br />
Uponor has added more<br />
products, is to float on the<br />
The company is making an<br />
order to meet estimated<br />
than 130 new jobs in the area<br />
London Stock Exchange.<br />
$18 million investment to<br />
growth for PEX tubing in<br />
over the past three years<br />
The company generated<br />
expand production of cross-<br />
plumbing, fire sprinkler,<br />
– taking the total to around 500<br />
sales of £173.1 million in<br />
linked polyethylene (PEX) pipe<br />
radiant heating and cooling<br />
– and expects to add more<br />
2014, and EBITDA of<br />
at the plant. The extra 88,000<br />
and hydronic piping systems<br />
following the expansion. This<br />
£26.1m. The profiles<br />
sq ft will accommodate new<br />
used in residential and<br />
year marks the compay’s<br />
division accounted for 42%<br />
equipment and office space.<br />
commercial structures.<br />
25-year anniversary in Apple<br />
of sales, and the building<br />
Construction is expected to be<br />
“It’s an exciting time in the<br />
Valley.<br />
plastics division 58%.<br />
finished by the end of the year.<br />
building industry, especially<br />
Uponor CEO and president<br />
Patrick Bateman, CEO of<br />
The company’s North<br />
after the downturn we<br />
Jyri Luomakoski added: “Our<br />
Eurocell, said: “Over the<br />
American headquarters are<br />
experienced just a few years<br />
North American region has<br />
last few years, Eurocell has<br />
also located in Apple Valley,<br />
ago,” said Bill Gray, Uponor<br />
consistently boosted profits<br />
developed a leading UK<br />
while it has a distribution<br />
North America president.<br />
and seized market share, both<br />
position in window, door and<br />
centre and resin-processing<br />
“We’re seeing significant<br />
in the residential commercial<br />
roofline PVC products. This<br />
centre in nearby Lakeville. By<br />
growth in commercial and<br />
segments.”<br />
is supported by our national<br />
year-end, the company’s<br />
residential construction, and<br />
❙ www.uponor-usa.com<br />
network of branded<br />
branches. This has enabled<br />
Uponor will expand its<br />
us to deliver adjusted<br />
North American plant<br />
EBITDA growth of 57.0%<br />
by 88,000 sq ft<br />
and 70.8% for the year<br />
ended 31 December 2013<br />
and 2014, respectively.”<br />
Eurocell was founded in<br />
the UK in 1974. It was<br />
owned by Tessenderlo of<br />
Belgium between 2008 and<br />
2013 – when it was acquired<br />
by H2 Equity Partners.<br />
❙ www.eurocell.co.uk<br />
Advanced Drainage Systems makes Ideal move<br />
Advanced Drainage Systems<br />
“The acquisition of Ideal<br />
competitive position compared<br />
adding to existing ADS factories<br />
(ADS), a global manufacturer of<br />
<strong>Pipe</strong> further strengthens our<br />
to manufacturers of concrete,<br />
in Ontario and Quebec.<br />
corrugated pipe, has acquired<br />
position in Canada by increas-<br />
steel and PVC pipe.”<br />
The acquisition also extends<br />
Ideal <strong>Pipe</strong> of Canada for<br />
ing our size and scale in the<br />
With the acquisition, ADS<br />
the combined company’s<br />
CAN$56.8 million (US$45.7m).<br />
market, and enhancing our<br />
increases its Canadian<br />
Canadian field sales and<br />
Ideal, which makes HDPE<br />
manufacturing, marketing and<br />
manufacturing footprint from<br />
engineering staff, allowing<br />
pipe and related accessories,<br />
distribution capabilities,” said<br />
two to five facilities.<br />
ADS to leverage products like<br />
had sales of CAN$43m<br />
Joe Chlapaty, chairman and<br />
Ideal has manufacturing<br />
its Allied line through Ideal’s<br />
(US$34.5m) for the last 12<br />
CEO of ADS.<br />
plants in Western Ontario,<br />
sales network.<br />
months.<br />
“This puts us in a stronger<br />
Eastern Ontario and Manitoba,<br />
❙ www.ads-pipe.com<br />
6<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
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news<br />
Fewer plastic pipe sites in Europe<br />
The number of plastic pipe<br />
extrusion sites in Europe has<br />
fallen by nearly a quarter in<br />
the last 15 years.<br />
According to AMI’s<br />
directory of plastic pipe<br />
extruders in Europe, there<br />
were 625 sites in 2001 and<br />
just 480 today – an overall<br />
reduction of 23%.<br />
In 2008, the total was 559<br />
sites – around 12% higher that<br />
today.<br />
The worst affected areas<br />
have been Spain, Italy, France<br />
and the UK – which accounted<br />
for 60-70% of the site<br />
Other<br />
Central<br />
Eastern Europe<br />
11%<br />
Other<br />
West Europe<br />
10%<br />
Benelux<br />
6%<br />
Nordic<br />
7%<br />
Spain<br />
7%<br />
Germany<br />
20%<br />
UK<br />
8%<br />
France<br />
9%<br />
Italy<br />
13%<br />
Distribution of plastic pipe<br />
production in Europe, 2014<br />
Source: AMI, <strong>2015</strong><br />
Poland<br />
9%<br />
reduction in Europe. The most<br />
common reason for plant<br />
closures has been either<br />
group rationalisation within<br />
a country or the transfer<br />
of production abroad.<br />
However, there have also<br />
been many bankruptcies<br />
and acquisitions resulting<br />
from liquidation.<br />
Germany is still Europe’s<br />
largest producer of plastic<br />
pipes, with 20% of production in<br />
2014. This has increased over<br />
recent years as it is the only<br />
West European country that has<br />
seen output recover to 2007<br />
levels of demand.<br />
European production of<br />
plastics pipes is still around<br />
20% below that of 2007.<br />
A second AMI report, a<br />
review of the market’s top 50<br />
players, puts Wavin (now part<br />
of Mexichem), <strong>Pipe</strong>life and<br />
Russia’s rapidly expanding<br />
Polyplastic in the top three<br />
positions.<br />
The top 10 companies<br />
account for 40% of production<br />
by volume. AMI estimates that<br />
the industry is worth around<br />
€7.5bn.<br />
❙ www.amiplastics.com<br />
Window<br />
maker sells<br />
division<br />
AmesburyTruth, a US-based<br />
manufacturer of window<br />
and door components, is to<br />
sell its non-fenestration<br />
custom extrusion business<br />
to VIP Rubber and Plastic<br />
Products.<br />
The 72,000 sq ft facility,<br />
in Ontario, California,<br />
employs 50 people and<br />
makes both fenestration and<br />
non- fenestration products.<br />
The company will now move<br />
its fenestration opeations to<br />
a facility in Minnesota.<br />
“Our goal is to be North<br />
America’s number one<br />
supplier of window and<br />
door components,” said<br />
AmesburyTruth president<br />
Jeff Graby.<br />
AmesburyTruth is a<br />
subsidiary of UK-based<br />
Tyman.<br />
❙ www.amesburytruth.com<br />
Fullerenes shown to protect<br />
plastics insulation in cables<br />
Researchers from Borealis and<br />
the Chalmers University of<br />
Technology in Sweden have<br />
demonstrated the use of<br />
fullerenes to protect plastics<br />
insulation in highvoltage<br />
cables.<br />
They say that the<br />
nanometre-sized<br />
carbon balls enable<br />
polyethylene to<br />
withstand a 26% higher<br />
voltage, which could<br />
increase the efficiency of<br />
power grids in the future.<br />
The research work involved<br />
the addition of very small<br />
amounts of different variants<br />
of the C 60<br />
carbon ball, a<br />
nanomaterial in the fullerene<br />
molecular group that is also<br />
known as a buckminsterfullerene<br />
or bucky-ball. Such<br />
materials have already been<br />
tested in the conductive parts<br />
of high-voltage cables, but it is<br />
Fullerenes can<br />
help to prevent<br />
the formation of<br />
electrical trees in<br />
high-voltage cable<br />
insulation<br />
believed that<br />
this is the first<br />
time that it has<br />
been shown they can bring<br />
benefits to the insulation<br />
material.<br />
The Chalmers researchers<br />
say that fullerenes are the best<br />
voltage stabilizers identified<br />
for insulation plastics thus far.<br />
They help to capture electrons,<br />
preventing them from<br />
destroying other molecules<br />
and forming electrical trees<br />
within the plastic.<br />
A paper on the initial<br />
research, entitled “A new<br />
application area for fullerenes:<br />
voltage stabilizers for power<br />
cable insulation”, has recently<br />
been published in the Advanced<br />
Materials journal. The next<br />
stage of the project will involve<br />
testing the technology on a large<br />
scale in complete high-voltage<br />
cables with both alternating<br />
current and direct current.<br />
❙ www.chalmers.se<br />
8<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
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Polyolefin developments | materials feature<br />
Separate testing procedures have found that polyolefin pipes are<br />
likely to last beyond 100 years – in both pressure and non-pressure<br />
applications. Lou Reade reports<br />
Reaching a century:<br />
polyolefin developments<br />
An independent project, commissioned by The European<br />
Plastic <strong>Pipe</strong>s and Fittings Association (Teppfa), has<br />
concluded that polyolefin sewer pipes have a service<br />
lifetime expectancy of at least 100 years. The results of<br />
the two-year project were scrutinised by Heinz Dragaun<br />
from the Technical School for Higher Education (TGM) in<br />
Vienna.<br />
The starting point for the project was that predicting<br />
life expectancy of pressure pipes is well documented,<br />
but this is not the case for non-pressure applications in<br />
sewage and drainage. The project studied pipes made<br />
from PE and PP-B by investigating thermo-oxidative<br />
degradation, maximum allowed stress, long-term<br />
behaviour under constant strain and the effect of sewer<br />
conditions (such as chemicals) and temperature.<br />
The project involved the excavation of many samples<br />
from in-service pipe networks, which were then tested<br />
and assessed in the laboratory. The findings are<br />
expected to favourably influence sewer operators that<br />
are faced with major capital investment in new or<br />
replacement networks, said Teppfa.<br />
“Designers, owners and operators of sewer networks<br />
can be confident that these sewer systems will<br />
have an in-service life of at least 100 years when<br />
materials, products and installation practices meet the<br />
appropriate requirements,” said Tony Calton, Teppfa<br />
general manager. “It will lend further appeal and allow<br />
polyolefin sewer pipes to be specified with increased<br />
confidence as they perform consistently throughout<br />
their very long asset life.”<br />
Many European countries have old sewer networks<br />
that need to be modernised or replaced. Life expectancy<br />
is a critical factor in any investment decision. Polyolefin<br />
pipe systems have been widely used for over 40 years<br />
and compared to non-plastic pipe materials, they have<br />
consistently offered a longer term solution. However,<br />
Dow’s PE-RT<br />
pipes have<br />
achieved the<br />
highest<br />
chlorine<br />
resistance<br />
classification<br />
www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 11
materials feature | Polyolefin developments<br />
A PE100+<br />
project aimed<br />
to evaluate butt<br />
fusion test<br />
methods for<br />
large PE pipe<br />
Dow’s Hypertherm<br />
2399<br />
PE-RT material<br />
allows<br />
installers to<br />
bend water<br />
lines at turning<br />
joints to ease<br />
installation<br />
whereas the life expectancy of polyolefin pipes has been<br />
discussed for many years, a definitive conclusion has<br />
never been determined.<br />
Excavated pipes that were tested had already been in<br />
use for up to 40% of their proposed in-service lifetime.<br />
The tests showed that no excessive deterioration or<br />
degradation has occurred over this time.<br />
“Although the oldest excavated pipes were manufactured<br />
using ‘first generation’ material formulations, a<br />
residual lifetime of more than 50 years was calculated,”<br />
said Calton. “And we should also bear in mind that<br />
current formulations offer even greater lifetime<br />
performance than those earlier materials.”<br />
Other key factors investigated in project were found<br />
not to affect life expectancy adversely. These included:<br />
the chemical composition of the sewer water; the<br />
temperature profile of sewer flows; and variations in the<br />
kind of installation practices used. The influence of<br />
higher concentrations of sewer effluent that are<br />
typically associated with structured wall pipe systems<br />
was also examined.<br />
The full technical report and a summary technical<br />
report are available on Teppfa’s website, as is a<br />
four-page leaflet outlining the project scope. The<br />
project was co-ordinated by Teppfa in conjunction with<br />
LyondellBasell, Borealis and TGM (Austria).<br />
Joining assessment<br />
PE 100+, the industry organisation for suppliers PE 100<br />
pipe materials, recently carried out a project to assess<br />
the joining – and testing – of large diameter, thickwalled<br />
PE pipe. It has been working to further develop<br />
test methods and harmonise global standards for butt<br />
fusion procedures, and endorse their suitability for this<br />
type of pipe.<br />
“Test methods for butt fusion welds are potentially<br />
misleading, and they exist in ISO, European and many<br />
national and industry standards,” said Steve Beech, who<br />
led the butt fusion harmonsation project.<br />
There are short-term destructive tests, which<br />
include a variety of tensile tests on small specimens cut<br />
from the weld, impact tests, pressure tests and tensile<br />
tests on whole pipe assemblies. Long-term tests<br />
include creep tests on full thickness specimens, Full<br />
Notch Creep Tests (FNCTs) and pressure tests on the<br />
pipe assembly.<br />
The key to success for the project has been the<br />
evaluation of test methods to fully understand shortand<br />
long-term properties of the welds. An important<br />
aim was to evaluate welds in large diameter, thick<br />
walled pipe with a range of wall thicknesses. This was<br />
done by short term, long term and Full Notched Creep<br />
testing.<br />
The minimum service life of the butt welds tested<br />
was estimated in accordance with Vogt et al. A maximum<br />
longitudinal stress of 4MPa, a result of the<br />
maximum design hoop stress of 8MPa for an unrestrained<br />
PE 100 pipeline, gives a conservatively<br />
estimated lifetime of 215 years at 20°C in water. Based<br />
on this calculation, it can be safely concluded that for<br />
water and gas applications at 20°C, a properly made PE<br />
100 butt fusion joint is predicted to achieve a service life<br />
well in excess of 100 years.<br />
Overall, the results of the project indicate that<br />
rationalisation and some harmonisation of the three<br />
procedures could take place – if the industry is willing<br />
to do this, said Beech.<br />
Bending round corners<br />
Dow has launched Hypertherm 2399, a polyethylene<br />
resin for domestic and commercial hot and cold water<br />
plumbing pipes. The PE-RT material enhances pipe<br />
flexibility, allowing installers to bend water lines at<br />
turning joints to ease installation.<br />
“Turning joints have always been a challenge when<br />
installing copper, steel and rigid plastic pipe,” said Oray<br />
Talu, market manager for Dow pipe and irrigation<br />
12<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
www.pipeandprofile.com
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materials feature | Polyolefin developments<br />
Sabic has<br />
completed its<br />
Vestolen A<br />
portfolio with<br />
an orange<br />
HDPE grade for<br />
gas distribution<br />
pipe<br />
products. “These are typically the first points of failure<br />
and a major contributor to call-backs.”<br />
Dow’s new material eliminates the need for breaks<br />
at joints, which reduces the likelihood of leaks.<br />
According to Dow, the resin is the first product to meet<br />
US building codes and product standards for plumbing<br />
while also achieving Level 5 chlorine-resistance certification.<br />
This accreditation gives contractors and homebuilders<br />
the flexibility to install continuous loop, on-demand<br />
recirculation, and traditional plumbing systems.<br />
The material can be used as a drop-in replacement<br />
for cross-linked polyethylene (PEX), with minimal<br />
tooling changes.<br />
At the same time, pipes made from Dow’s Dowlex<br />
2388 PR-RT resin have received the highest chlorine<br />
resistance certification (Class 5). The certification was<br />
issued by Jana Laboratories in Canada. The pipes were<br />
subjected to different temperatures and pressures at a<br />
chlorine concentration of 4.4 ppm and have been tested<br />
for more than two years until a failure could be<br />
observed.<br />
Meanwhile, Sabic has completed its Vestolen A pipe<br />
portfolio with a new orange high density polyethylene<br />
(HDPE) grade for gas distribution.<br />
The grade, Vestolen A 6060R, is long-lasting and can<br />
be used for mono- as well as for multi-layer co-extruded<br />
pipes. It has good resistance to slow crack growth<br />
and rapid crack propagation, as it is classified as a<br />
PE100 compound and comes with a 10.0 MRS (Minimum<br />
Required Strength) rating.<br />
The grade builds on the existing Vestolen A range<br />
which is known as a reliable, low weight and easy to<br />
install HDPE material, says Sabic.<br />
Louis Loos, segment leader for pipes at Sabic said:<br />
“We will continue to invest in the pipe industry, to anticipate<br />
its future developments and requirements.”<br />
Because die deposits are significantly reduced<br />
during the extrusion process of the new grade, it also<br />
offers benefits to converters as the production process<br />
does not need to be interrupted as frequently as when<br />
using standard material – meaning that higher levels of<br />
throughput can be achieved.<br />
“When developing new materials we pay particular<br />
attention to the conversion process. Vestolen A 6060R is<br />
an example of how we support converters to optimise<br />
their production process,” said Ralph Handstanger,<br />
technical marketing engineer for HDPE at Sabic Europe.<br />
Multi-layer performance<br />
Massimiliano Fenili, technical manager of Tecnomatic,<br />
told delegates at last year’s <strong>Pipe</strong>s in Infrastructure<br />
conference in Dusseldorf that multi-layer pipe can<br />
boost performance, and perform beyond the capability<br />
PEX guidance<br />
A 144-page design guide on cross-linked polyethylene (PEX) has recently been completely updated.<br />
The Residential PEX Water Supply Plumbing Systems Design Guide is now available online. The<br />
guide, which includes expanded information on green construction codes, can help homeowners,<br />
designers, builders, plumbers and architects plan and understand the features and benefits of a<br />
PEX pipe residential water system.<br />
It includes comprehensive design concepts and installation guidelines for the proper use of<br />
PEX pipe systems. The guide was a collaborative effort between the Plastics <strong>Pipe</strong> Institute (PPI),<br />
Home Innovation Research Labs, International Code Council (ICC) and Plastic <strong>Pipe</strong> and Fittings<br />
Association (PPFA), and can be downloaded from the websites of all four organisations.<br />
“This edition includes many enhancements to manage increased usage of PEX systems in a<br />
variety of residential applications such as water reuse and retrofitting,” said Randy Knapp,<br />
director of engineering of PPI’s Building and Construction Division (BCD).<br />
New information was added to almost every chapter including standards, all applicable<br />
national plumbing, mechanical, and building codes including new green construction codes, updates to fitting systems, and new<br />
design information on fixture flow rates and water hammer.<br />
14<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
www.pipeandprofile.com
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materials feature | Polyolefin developments<br />
System Group’s<br />
Sow Flow AMR<br />
pipe is intended<br />
for use in<br />
drainage<br />
systems on<br />
steep hills<br />
of single-walled pipe.<br />
He cited the case of Omani pipe extruder Muna Noor,<br />
which has commissioned an extrusion line from<br />
Tecnomatic to make multi-layer PE pipe – the first in<br />
the Middle East, it says. The line has an output of up to<br />
2000 kg/h, making pipes with a maximum diameter of<br />
1200mm.<br />
Muna Noor, part of Kuwait’s Boubyan Petrochemical,<br />
specialises in the production of PE pipe in sizes up to<br />
800mm. It recently opened a new factory in Sohar to<br />
produce PP double wall corrugated sewer pipes up to<br />
1200mm, plus fittings, manholes and PE multilayer<br />
safety pipes. The pipes are produced under a technology<br />
licence from Wavin Overseas.<br />
Multilayer pipe offers a practical solution to problems<br />
in the installation and jointing of PE systems, providing<br />
high security at minimum additional cost. By combining<br />
the best materials for specific loading conditions, they<br />
provide protection and long-time durability. The new<br />
generation of pipe will be ideal for the poor, stony soils<br />
of the Oman and other Middle East countries – which<br />
can produce high stresses in the pipe wall.<br />
One answer is to use High Stress Crack Resistance<br />
(HSCR) PE 100 materials – such as BorSafe HE3490-<br />
LS-H HSCR PE100 from Borouge in this project.<br />
The materials are ideal for rocky soil conditions<br />
where no imported pipe surround is available, and are<br />
equally resistant to Slow Crack Growth (SCG) caused by<br />
external surface damage and point loads. The materials<br />
can be used for pipes that are installed using a wide<br />
variety of trenchless technology – from the renovation of<br />
existing pipelines using insertion or pipe-bursting<br />
techniques, to installing new pipes using high speed<br />
ploughing or horizontal directional drilling.<br />
At the same event, System Group of Italy presented<br />
details of an HDPE pipe system that is engineered to<br />
make water flow more slowly – such as when it is<br />
running down a steep hill.<br />
Its corrugated HDPE pipes have an artificially<br />
introduced roughness on the inner surface, in order to<br />
hinder the flow of water. The system is called Slow Flow<br />
AMR. The pipe is the result of research at Bari Polytechnic.<br />
Marco Maroncelli, marketing manager, told delegates<br />
that the inner surface roughness leads to<br />
turbulence which limits the speed of water flow. The<br />
pipes can be combined with ‘vortex’ manholes to further<br />
reduce water velocity in sewage and drainage systems.<br />
l Proceedings for the conference are available for<br />
purchase here.<br />
Click on the links for more information:<br />
❙ www.teppfa.org<br />
❙ www.pe100plus.com<br />
❙ www.dow.com<br />
❙ www.sabic.com<br />
❙ www.tecnomaticsrl.net<br />
❙ www.boubyan.com (Muna Noor)<br />
❙ www.borouge.com<br />
❙ www.tubi.net (System Group)<br />
❙ www.plasticpipe.org<br />
❙ www.ppfahome.org<br />
❙ www.iccsafe.org<br />
❙ www.homeinnovation.com<br />
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• Multilayer cross heads for pipe coating applications<br />
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Screws & barrels | machinery feature<br />
New concepts in screws and<br />
barrels help to extend<br />
component lifetime and<br />
boost throughput<br />
Turning a profit:<br />
screws and barrels<br />
Screws and barrels are at the coalface of plastics<br />
processing, and are often the components that wear<br />
down first. So, enhancing wear resistance can be the<br />
first consideration for extending machine lifetime.<br />
Nordson Xaloy Europe has developed a bimetallic<br />
barrel alloy with enhanced resistance to corrosive and<br />
abrasive wear, which extends the working life of<br />
extrusion barrels in general-purpose applications.<br />
The key to the corrosion resistance of the X220 alloy<br />
is its higher chromium content relative to other barrel<br />
inlays for general-purpose use – twice that of Nordson<br />
Xaloy’s own X200 inlay and greater than the standard<br />
alloy in Europe, says the company. The new inlay also<br />
has greater hardness: 64 to 69 on the Rockwell HRC<br />
scale, versus 58 to 65 for the X200.<br />
In acid immersion tests of sample weight loss, X220<br />
alloy exhibited a 55% improvement over other European<br />
alloys in sulphuric acid and a 44% improvement in<br />
hydrochloric acid.<br />
“The new X220 inlay improves productivity and<br />
product quality through better screw-to-barrel fit,<br />
reduces downtime, and prolongs the working life of the<br />
barrel,” according to David Hotchkiss, global product<br />
manager.<br />
A bimetallic inlay is a high-hardness alloy that lines<br />
the inner wall of the barrel. As general-purpose inlays,<br />
the iron-based X200 and the iron-chromium-based X220<br />
can be used with a wide range of polyolefin, styrenic,<br />
and other resins at filler loadings up to 15%. For vinyls,<br />
certain fluoropolymers, and other potentially corrosive<br />
resins, Nordson Xaloy supplies the X306 nickel-cobalt<br />
alloy. The tungsten carbide/nickel-based alloy X800<br />
provides high wear and corrosion resistance for highly<br />
filled resins and high-temperature engineering<br />
polymers.<br />
Expanded output<br />
US-based Reiloy Westland – part of Germany’s<br />
Reifenhäuser since 2012 – is in the process of building a<br />
new facility to help it increase output of screws and barrels.<br />
The new plant, in Maize, Kansas, is eight miles<br />
from the company’s existing facility in Wichita and – at<br />
55,000 sq ft – more than twice its size.<br />
The company has already ordered a Weingärtner<br />
MPMC 600-6000 – a 5-axis, multi-purpose machining<br />
centre that will be used to make both screws and<br />
barrels.<br />
It will be delivered in July this year, by which time<br />
the new plant is expected to be ready.<br />
“It increases the dimensional capacity of the<br />
products we can manufacture,” the company said.<br />
The company intends to be very active at this<br />
year’s NPE, with a number of new products and<br />
concepts on show. For starters, it will introduce its<br />
new patent-pending mixing screw. Based on the<br />
Eagle mixing screw, which the company first<br />
introduced in 1991, it has undergone multiple<br />
redesigns over its history.<br />
s<br />
A new mixer<br />
screw from<br />
Reiloy Westland<br />
is based<br />
on its earlier<br />
Eagle screw<br />
Reiloy<br />
Westland’s<br />
NPE app will<br />
help visitors<br />
negotiate the<br />
show<br />
www.pipeandprofile.com <br />
<strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION<br />
19
machinery feature | Screws & barrels<br />
KraussMaffei<br />
Berstorff’s Eco-<br />
Line microwave<br />
channels have<br />
helped<br />
Trelleborg<br />
reduce energy<br />
costs<br />
The low-shear mixer – which Reiloy Westland sees<br />
as being appropriate to all types of plastics processing<br />
applications, including extrusion – provides both<br />
dispersive and distributive mixing, improves isothermal<br />
melt quality and increases throughput. The new concept<br />
will be seen at the show.<br />
“The projected quality mixing obtained, without<br />
introducing excessive shear, will offer improved<br />
profitability,” said the company.<br />
Another new concept is a special ‘NPE app’, which<br />
will allow visitors to make their visit to the event easier.<br />
As well as advice on travelling to Orlando and a guide to<br />
the city, users can register their attendance at the show<br />
and book appointments with the company.<br />
The app also includes the latest edition of the<br />
company’s Barrel and Screw Handbook.<br />
Microwave seal<br />
Sometimes, special applications dictate that the<br />
traditional approach of plasticising using a screw alone<br />
is not appropriate. This was the case with Trelleborg, a<br />
Swedish producer of sealing profiles for the automotive<br />
and building industries – which has begun using two<br />
EcoLine microwave channels from KraussMaffei<br />
Berstorff.<br />
Trelleborg first saw the technology in action at a<br />
KraussMaffei open house event, and signed the<br />
purchase order for the two lines at K2013. The reason<br />
for the investment was to reduce operating costs in the<br />
energy-intensive vulcanization process.<br />
“In view of the results – in terms of productivity and<br />
quality – we decided to opt for this solution to further<br />
increase our productivity,” said Joakim Hansson,<br />
purchasing manager at Trelleborg.<br />
Four microwave channel modules are each equipped<br />
with a generator of 6kW magnetron power. A circulator<br />
integrated into the energy supply transfers any energy<br />
not absorbed by the product to the connected water<br />
load, to improve magnetron service life.<br />
The channel has a total installed magnetron power<br />
of 24kW. The microwave generators are arranged above<br />
and below the conveyor belt. The microwave coupling<br />
system is designed to ensure a homogeneous field<br />
distribution. Both the microwave power and conveyor<br />
belt speed can be continuously adjusted. The microwave<br />
channel has an effective cross-section of 280mm width<br />
and 150mm height.<br />
A central control panel ensures that system settings<br />
can be selected with ease. A process-oriented user<br />
interface helps to reduce set-up times during material<br />
changes.<br />
“Special features of the EcoLine microwave channel<br />
are reduced waste gas losses and the energy-optimised<br />
switched-mode power supplies,” said Helmut Lüders,<br />
product manager for rubber profile production lines at<br />
KraussMaffei Berstorff.<br />
“Closed circulation of the process air provides<br />
maximum cost savings, as 90% of the energy-intensive<br />
hot air remains in the system.”<br />
Another new feature is improved thermal insulation<br />
of the process chambers, he said.<br />
Nordson Xaloy’s bimetallic barrel alloy shows high resistance to acid<br />
immersion<br />
Click on the links for more information:<br />
❙ http://reiloyusa.com<br />
❙ www.nordsonpolymerprocessing.com<br />
❙ www.kraussmaffeiberstorff.com<br />
20<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
www.pipeandprofile.com
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Mixers for PVC | machinery feature<br />
Creating a stir with<br />
the latest mixers<br />
Pat Toensmeier reports<br />
on recent developments in<br />
continuous and batch mixers, including<br />
improvements in rotor and machine designs<br />
Suppliers of batch and continuous mixers are developing<br />
improved machine designs to meet compounders’<br />
changing demands to produce the latest materials<br />
formulations more efficiently. These requirements<br />
include:<br />
l Material versatility and innovation: Compounders are<br />
running more specialty resins and ingredients, and in the<br />
process dealing with formulations that need fine-tuning<br />
to achieve the required properties. Mixers are being<br />
upgraded with special equipment and capabilities that<br />
allow process tailoring for creating innovative materials.<br />
l Higher throughput: Increased productivity means an<br />
improved return on investment, but only if materials<br />
meet quality standards. Mixing systems are being<br />
engineered for high throughputs, notably in screw, rotor<br />
and mixing-blade designs that boost output with no<br />
trade-offs in quality.<br />
l Energy efficiency: Cost savings go right to the bottom<br />
line. In some countries, reductions in energy also<br />
satisfy regulatory standards.<br />
l Automation: Reducing manual input saves money and<br />
assures consistent quality in batch and continuous<br />
machines.<br />
l Profitability: Many high-tech compounds go into<br />
commodity applications, putting downward pressure on<br />
production prices. The ability of mixing to improve<br />
margins is an important tactic in a strategy aimed at<br />
increasing profitability.<br />
Over the following pages we review recent continuous<br />
and batch mixer developments from Farrel Pomini,<br />
TPEI, Ajax Equipment, B&P Process Equipment, Mixaco,<br />
Promixon and Marion Mixers.<br />
Continuous improvements<br />
Recent developments at Farrel Pomini include the<br />
extension of the CP (Compact Processor) Series II range<br />
of continuous mixers. Launched this year, the CP4000<br />
achieves a nominal throughput of 4,000 kg/hour (8,800<br />
lb/hr) and bridges the gap between modular continuous<br />
mixers that are integrated into a unitized frame, and the<br />
company’s higher-output non-unitized designs that can<br />
process materials at rates above 6,000 kg/hour.<br />
The CP4000 is the seventh and final model in the<br />
line, says Paul Lloyd, business unit director at Farrel in<br />
the US. This is because the unitized frame of the<br />
modular series cannot be duplicated for higher output<br />
mixers. “Any mixer with throughput above 4,000 kg/hour<br />
will require different construction,” he explains. “The<br />
Farrel Pomini’s<br />
new CP4000<br />
mixer has a<br />
number of<br />
process<br />
variables that<br />
improve mixing<br />
and throughput<br />
www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 23
machinery feature | Mixers for PVC<br />
Farrel Pomini’s CP4000 bridges the gap<br />
between standard continuous mixers<br />
and non-unitized, high-output<br />
models<br />
CP4000 is the maximum size for this platform concept.”<br />
Two CP4000 mixers have been sold to undisclosed<br />
compounders in Europe, Lloyd reports. The new larger<br />
model is more expensive than previous sizes, as you’d<br />
expect, but is claimed to deliver a better return-oninvestment.<br />
“Volume helps [the bottom line] in our<br />
business. Customers can expect lower cost per<br />
kilogram and better ROI with the CP4000,” he says.<br />
CP Series II sizes range from 125 to 4,000 kg/hour<br />
– the number of each machine denotes nominal<br />
throughput in kilograms. Each system has an integrated<br />
mixer and extruder, as well as a controller that<br />
regulates upstream and downstream equipment.<br />
Systems are wired, piped, pre-tested and shipped ready<br />
for installation.<br />
The mixer mounts on top of the frame and accepts<br />
multiple feed systems and material types. It has a<br />
gravity chute through which processed material<br />
FR rotors from discharges to a hot-feed extruder below. This is<br />
TPEI are equipped with a pumping screw (to minimize heat<br />
installed with build-up), screen-changer and pelletizing system.<br />
couplings, so Each mixer is equipped with twin-lobe, elliptic,<br />
the driveshaft counter-rotating, non-intermeshing rotors that produce<br />
bearing block distributive mixing while maintaining short residence<br />
doesn’t need to time and, consequently, a low heat history in materials<br />
be accessed and lower-than-average energy use.<br />
Two rotor versions are available for the mixers: the<br />
standard FCM (48 to 203.2 mm in<br />
diameter), and a CPXL or extra-long<br />
version optimized for high<br />
filler loadings, temperaturesensitive<br />
materials and<br />
reduced energy use. The FCM<br />
rotors have 6:1 L/D ratios,<br />
while CPXL versions have two<br />
stages and 10:1 ratios.<br />
The mixers handle diverse<br />
materials. These include: highly filled and pigmented<br />
polyolefins, PVC, styrenics, polyamides, polyesters,<br />
polycarbonate and thermoplastic elastomers (TPEs);<br />
calcium carbonate, titanium dioxide, carbon black and<br />
colorant masterbatches; flame-retardant compounds;<br />
recyclates; and biopolymers.<br />
Self alignment<br />
An important feature of the CP machines is their<br />
modularity, and Farrel Pomini has been adding<br />
components to optimize processing. The latest is the<br />
Self-Aligning Seal (SAS), which was developed by R&D<br />
manager Stuart Sardinskas based on customer<br />
feedback. The device provides a solid mechanical seal<br />
that keeps pellets and powders within the feed section<br />
of the mixing chamber.<br />
The SAS uses an air cushion to automatically align<br />
with the outer-diameter clearance of the rotor shafts.<br />
This maintains an impervious seal that prevents<br />
material migration. Lloyd says that although the CP<br />
mixers are designed for starve-feeding, they sometimes<br />
back up, which is when the seal is especially useful.<br />
The device is available on new machines and as a<br />
retrofit.<br />
Other components allow compounders to fine-tune<br />
processing. Farrel Pomini has long maintained that by<br />
adjusting a handful of process variables – feed rate,<br />
rotor speed, chamber temperature and the throttle gate<br />
output – its continuous mixers can produce a range of<br />
compounds without changing their hardware.<br />
Adjustable mixing-dam assemblies, for example, can<br />
be raised or lowered as necessary to restrict flow and<br />
thereby increase energy and shear during mixing,<br />
rather than wait until material reaches the orifice,<br />
which regulates discharge to the extruder. They can<br />
also be configured to accept ports for additives.<br />
A vent plunger regulated by a timer can be added at<br />
the end of the mixer to automatically vent moisture and<br />
other volatiles while enhancing throughput rates. Lloyd<br />
says the device is more efficient than conventional<br />
stationary vents, which may clog during operation and<br />
require immediate cleaning.<br />
▲<br />
24<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
www.pipeandprofile.com
You make<br />
great things.<br />
We make great<br />
things happen.<br />
In <strong>March</strong> <strong>2015</strong>, more than 60,000 professionals from every aspect of the<br />
plastics industry and its vertical and end-user markets will assemble in<br />
Orlando, Florida for the largest, most influential plastics event of the year.<br />
Expect great things.<br />
Register for free today at www.npeguestpass.org/<strong>Pipe</strong>2<br />
NPE<strong>2015</strong>: THE INTERNATIONAL PLASTICS SHOWCASE<br />
<strong>March</strong> 23-27, <strong>2015</strong><br />
Orange County Convention Center<br />
Orlando, Florida USA<br />
Face-To-Face, NPE2012
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• Type and size of pipes<br />
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Mixers for PVC | machinery feature<br />
The orifice is adjustable to control melt<br />
residence time. The device opens to<br />
whatever degree is necessary to<br />
increase or decrease work to the<br />
material prior to discharge.<br />
Free rotor<br />
Another supplier of continuous<br />
mixers, Technical<br />
Process & Engineering Inc<br />
(TPEI) continues to upgrade<br />
and expand a design it<br />
commercialized several years<br />
ago – its Free Rotor (FR)<br />
machines.<br />
FR rotors are three-piece<br />
constructions that are installed<br />
without opening a machine’s driveshaft<br />
bearing block. This is possible because<br />
the rotor shafts are separate from the rotor body. The<br />
rotor itself is installed with couplings, says engineer<br />
Jim Hower. This facilitates installation and doesn’t<br />
expose bearings to contaminants.<br />
FR models also come in extended FRE versions,<br />
which lengthen the rotor body by 1 L/D. Hower says this<br />
permits an extension of the feed chamber, which<br />
improves the feeding and processing of lightweight and<br />
other hard-to-feed materials such as recyclate.<br />
Eight models of the FR and FRE mixers are available<br />
– two in FR configurations and six in FRE versions.<br />
Hower points out that TPEI’s rotors evenly disperse<br />
highly loaded materials such as colour concentrates.<br />
Some formulations have an 85/15 ratio of concentrate<br />
and base material.<br />
One continuous mixer that utilizes innovative<br />
technology to optimize process capabilities is the<br />
TriVolution line of single-screw machines from B&P<br />
Process Equipment. The system achieves dispersive<br />
and distributive mixing. It also allows controlled shear<br />
mixing with high surface area regeneration for devolatization<br />
and reactive processing of materials.<br />
The unit performs these and other capabilities by<br />
blending the mixing features of a reciprocating kneader<br />
with those of a twin-screw extruder, says Michael<br />
Lazorchak, global product manager for mixing systems.<br />
But there is a twist. Whereas reciprocating kneaders<br />
allow one stroke (a forward and backward movement)<br />
per screw revolution, the TriVolution mixer generates<br />
three stokes for every 360˚ revolution of the screw, to<br />
broaden mixing flexibility.<br />
The screw can be configured with up to 12 intermeshing<br />
flights to modify mixing. Stationary pins<br />
inside the barrel create what Lazorchak describes as a<br />
“slalom effect” on the melt as it undergoes<br />
shearing, decompression, folding and<br />
elongational mixing.<br />
“The stroke of the machine is not<br />
adjustable, but the geometry is,” he<br />
explains. A compounder tailors<br />
mixing parameters by adjusting<br />
elements on the screw. “You can<br />
configure units according to<br />
the process you run.”<br />
Moreover, kneading and<br />
splitting of the melt, caused<br />
by the screw and stationary<br />
pins as it travels down the<br />
barrel, opens and exposes<br />
material to grafts and reactive<br />
processing. It also facilitates venting<br />
moisture and volatile gases. This is useful<br />
for compounds that contain natural fibres,<br />
which typically have high moisture content.<br />
In addition to producing a high-quality melt, the<br />
process minimizes the heat and energy in mixing. As<br />
B&P explains, the mechanical energy used for melting<br />
and mixing does not come from aggressive shear-inducing<br />
devices but from elongational mixing that takes place<br />
in the intermeshing areas between the stationary pins<br />
and reciprocating screw flights. There is, as a result, less<br />
material degradation, as well as cost savings.<br />
Six models are in the TriVolution line, with screw<br />
diameters of 30 to 160 mm and L/D ratios of 12, 16 and<br />
20:1 for each.<br />
Batch benefits<br />
Promixon of Italy reports developments in equipment<br />
and product distribution. The company has made a<br />
number of upgrades to its batch mixing systems and<br />
components, and in September inaugurated a venture<br />
with US-based Exline to distribute custom mixing<br />
B&P says that<br />
its TriVolution<br />
combines the<br />
mixing features<br />
of a reciprocating<br />
kneader<br />
with those of a<br />
twin-screw<br />
machine<br />
Promixon has<br />
upgraded<br />
mixing tools to<br />
improve<br />
material<br />
distribution,<br />
reduce wear<br />
and save energy<br />
www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 27
machinery feature | Mixers for PVC<br />
Batch unit from<br />
Marion Mixers<br />
uses WaveMix<br />
microwave<br />
heating system,<br />
which is fast,<br />
thorough and<br />
energy efficient<br />
Promixon’s TRX<br />
container mixer<br />
is designed for<br />
a range of<br />
materials<br />
including<br />
masterbatches,<br />
additives and<br />
polymers<br />
plants and spare parts in<br />
America. CEO Marco Marinello<br />
also says that the company will<br />
soon add “an innovative on-line<br />
service for spare parts<br />
management and technical<br />
support.”<br />
Developments that back up<br />
these initiatives include mixing<br />
tools with enhanced performance,<br />
25% increased cooling<br />
efficiency in the CMX cooling<br />
system, and greater energy<br />
savings in all mixing equipment.<br />
Marinello also says<br />
Promixon has added to its<br />
range of machines to meet<br />
the “enormous variety of<br />
mixing requirements” from customers.<br />
The company has increased the coating, thickness<br />
and incidence angle of the bottom blade of its mixing<br />
tool. This permits mixing at lower speeds when<br />
necessary, reduces wear to the tool and mixing tank,<br />
and reportedly assures optimum material distribution<br />
and dispersion. Promixon has also developed wearresistant<br />
coatings to extend mixer life. Engineers have<br />
also increased discharge diameters to raise throughput<br />
speed and batch productivity.<br />
One important development has been engineering<br />
mixers for greater reliability. Marinello says that as a<br />
result, customers will have “minimal maintenance<br />
costs in the first five years of use.”<br />
Mixers can be used with a range of thermoplastics,<br />
additives, masterbatches, colorants, bio-based composites<br />
and recyclate. Promixon’s best-selling models are<br />
the Problend-TC dry-blending system for PVC, with<br />
throughput of 400 to 9,000 kg/hr, and the TRX container<br />
mixer, for colour masterbatches and additives,<br />
with output of 60 to 1,000 kg/batch.<br />
The Problend-TC is said to be efficient and<br />
low cost to operate, while the TRX mixer<br />
affords easy cleaning and fast changeover.<br />
Alternative heating<br />
Marion Mixers produces batch and continuous<br />
machines and components<br />
to improve process operations.<br />
One notable technique<br />
the company promotes for<br />
horizontal mixers processing<br />
free-flowing materials is<br />
microwave (MW) heating.<br />
Called WaveMix technology,<br />
the process replaces conventional<br />
jacketed heating elements, says Nick<br />
Burkle, WaveMix specialist, and is<br />
reportedly faster and more effective than standard<br />
mixer heat systems, while consuming less energy.<br />
The company licensed the process from the<br />
University of Northern Iowa in the US two years ago.<br />
Burkle says an installation uses a 75- to 400-kW<br />
microwave transmitter operating at 915 MHz in a<br />
stainless steel vessel specially designed by Marion for<br />
safety. The process, which is scalable, yields even<br />
heating across the material.<br />
In a test carried out earlier this year, Marion reported<br />
that microwave-assisted drying was tested on 500 lb<br />
(230 kg) of agricultural-grade limestone powder, using a<br />
75-kW, 915-MHz transmitter in a 10-ft 3 batch mixer. The<br />
MW heat achieved moisture content of less than 0.05%<br />
(500 ppm) at 171°F (77.2°C) in less than 30 minutes.<br />
More information<br />
Michael Lazorchak of B&P Process Equipment and Jim<br />
Preston of Rhetech gave a presentation on “Putting the<br />
TriVolution mixer through its paces” at the Compounding<br />
World Forum 2014, which took place on 9-10<br />
December in Philadelphia, PA, USA. A selection of<br />
leading mixer suppliers were also exhibiting at the<br />
event, including B&P, Farrel Pomini, Mixaco, Promixon<br />
and TPEI. For conference proceedings, contact Kelly<br />
Cressman (kc@amiplastics-na.com).<br />
Click on the links for more information:<br />
❙ www.farrel-pomini.com<br />
❙ www.tpei.com<br />
❙ www.bpprocess.com<br />
❙ www.promixon.com<br />
❙ www.exline-inc.com<br />
❙ www.marionmixers.com<br />
28<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
www.pipeandprofile.com
AMI at NPE <strong>2015</strong><br />
Stand W8283<br />
Orange County Convention Center, Orlando from 23-27 <strong>March</strong><br />
Stop by to find out more about our conferences,<br />
publications and free magazines<br />
Contact Matt Wherlock, mjw@amiplastics.com<br />
for more information
NPE <strong>2015</strong><br />
| show preview<br />
The leading US<br />
plastics exhibition<br />
kicks of this month.<br />
We look at why NPE<br />
<strong>2015</strong> is shaping up<br />
to be huge success,<br />
and preview a<br />
selection of new<br />
products that will<br />
be on show<br />
NPE: lifting off in Florida<br />
NPE <strong>2015</strong>, which takes place on 23-27 <strong>March</strong> in<br />
Orlando, Florida, is likely to be the largest US plastics<br />
exhibition ever. More than 60,000 visitors are expected<br />
to view displays by some 2,000 exhibitors over more<br />
than 106,000m 2 of exhibition space. And according to<br />
show organiser, the US Society of the Plastics Industry<br />
(SPI), more than 400 of those exhibitors will have<br />
equipment running on their stands.<br />
“With so many exhibitors operating equipment, the<br />
show floor will be a dynamic panorama of manufacturing<br />
in action,” said Gene Sanders, SPI’s senior vice<br />
president of trade shows and conferences.<br />
NPE 2012 took place as the US economy began its<br />
recovery from the downturn. Exhibitor mood was<br />
optimistic then and is, perhaps, even better now as the<br />
US economy is performing well. While the IMF recently<br />
downgraded its forecast for global growth for <strong>2015</strong> to<br />
3.5%, the US was the sole major world economy to see<br />
its economic performance expectation lifted (from 3.1%<br />
to 3.6%).<br />
The most recent data from the SPI’s Committee on<br />
Equipment Statistics (CES) shows that US quarterly<br />
plastics machinery shipments have been running at<br />
near record levels now for close to three years. In the<br />
third quarter of last year, shipments of primary<br />
processing equipment totalled US$304.1 million. That<br />
was only 2% below the 10-year record result for the<br />
same period in 2013 and 6% ahead of the second<br />
quarter 2014 figures. Sales of twin-screw extruders in<br />
the US grew particularly strongly last year – they were<br />
35% higher during the first three quarters of 2014<br />
compared to the same period in 2013.<br />
More evidence of growth in the US plastics market<br />
can be found in the latest data from Germany’s<br />
machinery association, the VDMA. It reports that<br />
German exports of plastics and rubber processing<br />
machinery to the US grew 15.5% in 2013 to reach<br />
€630.4 million. This was the fourth consecutive year of<br />
strong growth since the downturn of 2009.<br />
Total world exports of plastics and rubber processing<br />
machinery to the US reached €2,020.4 million in 2013, up<br />
8.6% compared to 2012, according to statistics compiled<br />
by the VDMA using export figures from national statistical<br />
offices in 52 countries. Germany had the largest share of<br />
this market at 31.2%, followed by Canada (18.0%), Japan<br />
(14.6%), France (8.0%), China (5.4%), and Italy (5.2%).<br />
Over the following pages, we take a look at some of<br />
the materials, machinery and equipment relevant to pipe<br />
and profile extruders. If you’re at the exhibition yourself,<br />
please visit us at the Applied Market Information stand<br />
(W8283). We will also be touring the halls and tweeting<br />
news live from the show via our @PlasticsWorld Twitter<br />
feed.<br />
More details about visiting NPE <strong>2015</strong>, including<br />
opening times, advanced registration, travel information<br />
and accommodation booking, can be found on the<br />
exhibition website:<br />
❙ www.npe.org<br />
▲<br />
More than<br />
60,000 visitors<br />
are expected to<br />
view displays<br />
from 2,000<br />
exhibitors at<br />
NPE <strong>2015</strong><br />
www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 31
show preview | NPE <strong>2015</strong><br />
Coperion<br />
K-Tron’s dual<br />
blower rail<br />
unload system<br />
transfers<br />
powders,<br />
granules or<br />
pellets<br />
E-Plus dryers<br />
from Dri-Air<br />
Industries offer<br />
faster, more<br />
complete<br />
drying of<br />
plastics<br />
Ancillaries<br />
Coperion K-Tron will show a range of bulk<br />
materials handling systems at NPE this month, ranging<br />
from unloading, feeding and pelletising equipment<br />
through to packaging and loading systems.<br />
Its dual-blower Rail Unload<br />
System pneumatically transfers<br />
pellets, powders and granular<br />
materials from railcars at rates<br />
in excess of 120,000 lb/<br />
hour (54,000 kg/hour).<br />
Using separate vacuum<br />
and pressure blowers,<br />
the system is designed<br />
to unload<br />
materials from the<br />
railcar at higher conveying<br />
rates and for longer conveying distances.<br />
Coperion K-Tron’s modular loss-in-weight<br />
(LIW) feeders are designed for materials with<br />
varying bulk density and for automated materials<br />
handling. The S100 single-screw LIW feeder offers feed<br />
rates from 0.4 to 560 ft³/hour (10 to 15,800 dm³/hour)<br />
and can handle free-flowing powders, granules, and<br />
pellets. The T35 twin-screw LIW Feeder offers feed<br />
rates from 0.04 to 88.0 ft³/hour (1.25 to 2,500 dm³/hour)<br />
and is designed to cope with floodable powders and<br />
more difficult, sticky or hard-to-flow materials.<br />
❙ www.ktron.com<br />
E-Plus dryers from Dri-Air Industries<br />
claim to offer faster, more complete<br />
drying of plastics, with high energy<br />
efficiency. Their parabolic tower design,<br />
special heater configuration and optimised<br />
air flow maximize moisture pickup for<br />
ultra-low dew points, faster drying, and<br />
reduced regeneration energy usage, says<br />
the company. Greater hopper insulation<br />
further improves their efficiency, even<br />
with the most challenging, hard-to-dry<br />
plastics. They are available in three sizes,<br />
with capacities of 25, 50, or 100lbs/hour.<br />
❙ www.dri-air.com<br />
FB Balzanelli is to exhibit its TR1200C<br />
automatic coiler, which is highly flexible and<br />
suitable for coiling a variety of pipes. Most commonly<br />
used for corrugated pipes, PE gas and pressure<br />
pipes and PEX pipes up to 1in, the TR1200C has a<br />
compact design, user friendly functions and interface,<br />
and fully automated real time adjustment.<br />
Highlights include: quick installation, thanks to its<br />
compact design; 12in touch screen with diagnostic<br />
alarms; precision pipe guide to ensure a compact coil,<br />
saving on transport costs; a third-generation pneumatic<br />
strapping head design, for high reliability and efficiency;<br />
minimal maintenance; and, short payback time.<br />
❙ www.fb-balzanelli.it<br />
Herbold Meckesheim has redesigned its SMS<br />
Series granulators to cope with the most demanding<br />
heavy-duty size reduction applications in a single step.<br />
The machines are made with rotor widths ranging from<br />
23.5 to 78.75in, and with drive capacities of 60-420HP.<br />
The knife design is segmental, ensuring a quick and<br />
easy exchange of the cutting tools.<br />
SMS Granulators are equipped with a third bed knife<br />
called a deflection wedge. When the deflection wedge is<br />
removed larger, bulky items can be easily accommodated.<br />
Typical applications for these granulators are: heavy,<br />
thick-walled semi-finished products in PE, PP, POM and<br />
PA; pipes with high wall thicknesses; and large<br />
purgings.<br />
❙ www.herboldusa.com<br />
Test equipment supplier Instron will exhibit its new<br />
Advanced Video Extensometer (AVE 2), which conforms<br />
to the rigorous ISO 527-2 and ASTM D638 standards. It<br />
is a fully-integrated device that adapts to the<br />
normal fluctuations of environmental<br />
conditions in the lab and is easily<br />
adapted to any testing machine<br />
that uses a ±10V analogue input<br />
(performance depends on the<br />
system). Designed to reduce<br />
errors from thermal and lighting<br />
variations that are common in<br />
most labs, it is the only device on<br />
the market to use the real-time<br />
490Hz data rate while achieving a 1<br />
micron accuracy, says Instron.<br />
NPE visitors will also see<br />
Instron’s AutoX Automatic Contacting<br />
Extensometer that offers faster,<br />
more reliable and more accurate<br />
materials testing routines. Its high<br />
accuracy and travel make it ideal for tensile<br />
and flexure testing of plastics. Meeting the<br />
requirements of ISO 527-2, it is used to determine a<br />
variety of calculations including modulus, offset yield<br />
and plastic (non-proportional) elongation to failure.<br />
❙ www.instron.com<br />
s<br />
32<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
www.pipeandprofile.com
<strong>2015</strong><br />
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A strategic review of the prospects<br />
for the global plastics industry<br />
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30th April <strong>2015</strong> Philadelphia USA<br />
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9th June <strong>2015</strong> Cologne Germany<br />
29th October <strong>2015</strong> Cologne Germany<br />
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NPE <strong>2015</strong><br />
| show preview<br />
Moretto will showcase its enhanced Eureka drying<br />
system at NPE. The system comprises a Flowmatik<br />
airflow management and distribution system, OTX<br />
hopper dryer and the X Max dryer.<br />
Moretto says Eureka is “the most advanced drying<br />
system for engineering thermoplastics” and the only<br />
drying system that can process 10,000-12,000kg/h of<br />
material in compounding, extrusion and PET processing.<br />
Here, the company claims, it has around half the<br />
energy consumption of traditional drying systems.<br />
The core X Max dryer is based on Moretto’s patented<br />
‘X technology’ and incorporates a multibed single<br />
molecular sieve desiccant system providing constant<br />
-65°C to -85°C dew point. Though twice the size of<br />
conventional beds, it works without needing cooling<br />
water or compressed air for the changeover valve, and<br />
also recovers energy by cooling of the bed during<br />
molecular sieve regeneration.<br />
A key enhancement in the latest X Max dryer within<br />
the Eureka system is its multi-stage centrifugal blower,<br />
developed by Moretto in cooperation with nearby Padua<br />
University.<br />
Due to these combined features, the X Max drier is<br />
highly efficient: the X Max 916 model provides each unit<br />
with up to 1,600m³/h drying capacity at 300 mbar<br />
pressure with an electricity consumption of 13.2kWh.<br />
❙ www.moretto.com<br />
NDC Technologies says it has developed the<br />
industry’s first four-axis diameter and ovality gauge for<br />
products up to 12mm. Its Beta LaserMike AccuScan<br />
6012 enables manufacturers to measure product<br />
diameter and ovality with higher accuracy than two- and<br />
three axis gauges.<br />
The company says that manufacturers of medical<br />
tubing, high-performance cable and other extruded<br />
products – who have previously relied on two- and<br />
three-axis diameter and ovality gauges for on-line and<br />
off-line measurement – will benefit from the product,<br />
thanks to its ability to make precise measurements at<br />
increasing production line speeds.<br />
Making an “out-of-tolerance” medical tubing product<br />
can affect the performance of devices such as catheters,<br />
while errors in the diameter or roundness of the<br />
conductor or insulation in Coaxial and twisted-pair LAN<br />
products directly affects the cable’s performance<br />
characteristics – rendering it useless for the designed<br />
application.<br />
“This unusable product winds up being scrapped,<br />
increasing manufacturing costs,” according to the<br />
company.<br />
❙ www.betalasermike.com<br />
The Bessemer series of downstream equipment from<br />
Novatec now includes modular stainless steel<br />
vacuum tanks. These tanks are built in 4ft and 8ft<br />
lengths with 12 x 12in and 8 x 8in cross sections.<br />
Their modularity allows them to be connected<br />
to create whatever length profile<br />
extruders need. In the past, this<br />
type of tank was built-to order,<br />
which resulted in long lead<br />
times and high cost.<br />
These vacuum tanks will be<br />
stocked in the 4ft and 8ft<br />
lengths so they can be shipped<br />
quickly and in reasonable<br />
lengths (to reduce shipping costs)<br />
and easily connected in the<br />
processing plant.<br />
❙ www.novatec.com<br />
OMP, one of the companies in the NPE<br />
Startup Garage, has a mission to help<br />
extruders improve product identification,<br />
using digital colour printing to mark PVC products such<br />
as pipe.<br />
Company founder Jim Vitous previously spent more<br />
than 30 years in the product identification industry. The<br />
company’s name is derived from the phrase ‘One<br />
Moving Part’ – as its technology has a single rotating<br />
component.<br />
“The resulting solution provides an integrated<br />
simplified printing experience that will displace the<br />
cumbersome ink jet technologies currently in place,”<br />
said Vitous. “The consumer’s perceived value will be<br />
raised significantly.”<br />
❙ www.pvcpipeprinter.com<br />
R&B Plastics Machinery will use NPE as the<br />
launchpad for its Max extrusion control system. This<br />
uses an economical Windows CE-based human machine<br />
interface (HMI) system that provides performance<br />
similar to SCADA software systems, according to R&B.<br />
Featuring Allen Bradley and Ifix systems, the Max<br />
control platform can provide integrated line control for<br />
a wide range of extrusion applications, including<br />
compounding and recycling. It provides control of<br />
temperature, speed and pressure with the touch of a<br />
screen. Integration of upstream and downstream<br />
equipment is also available.<br />
The system is customised to meet end-user requirements,<br />
including the selection of hardware suppliers. It<br />
can be retrofitted to all makes of extruders and can also<br />
be used with R&B’s own Max extruder product line.<br />
❙ www.rbplasticsmachinery.com<br />
s<br />
Novatec’s<br />
Bessemer<br />
series of<br />
downstream<br />
equipment now<br />
includes<br />
modular<br />
stainless steel<br />
vacuum tanks<br />
www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 35
show preview | NPE <strong>2015</strong><br />
Aurora’s<br />
capstock is<br />
designed to<br />
withstand<br />
weathering<br />
over the long<br />
term, even in<br />
dark colours<br />
Materials<br />
Aurora Plastics has introduced a weatherable PVC/<br />
acrylic alloy capstock. The product is designed to<br />
withstand the effects of weathering over the long term,<br />
even in dark colours, offering an attractive alternative<br />
for a variety of demanding applications such as outdoor<br />
trim, windows, decks, siding, fencing, and railing. It<br />
offers superior processing characteristics<br />
that translate into a more<br />
consistent coating, less scrap,<br />
faster startup and a<br />
broader processing<br />
window, says the<br />
company.<br />
“We identified a<br />
need for a more<br />
cost-competitive,<br />
long-lasting solution,” said<br />
Matthew Kuwatch, vice president of marketing and<br />
business development. “There are currently many<br />
options available, but most do not offer the same level<br />
of long-term weatherability and resistance to water<br />
whitening, especially in darker colours.”<br />
❙ www.auroraplastics.com<br />
Kureha America will show a range of KF Polymer<br />
PVDF grades at NPE <strong>2015</strong>.<br />
The material is a versatile fluoropolymer that is<br />
easily melt-processed. It has a long history of use for<br />
extruded and injection moulded piping and liquid<br />
handling components such as fittings and valves.<br />
It is now receiving increasing interest in oil and gas<br />
transport as a piping and lining material, and for water<br />
treatment systems for manufacture of ultrafiltration<br />
media, says Kureha.<br />
Benefits of the material include: chemical inertness;<br />
retention of mechanical properties from 23°C to 150°C;<br />
abrasion resistance; low coefficient of friction; thermal<br />
ageing resistance; resistance to UV and gamma<br />
radiation; and, conformance with CFR 177.2510 for food<br />
contact.<br />
❙ www.kureha.com<br />
Orion Engineered Carbons will showcase new<br />
speciality carbon blacks for pressure pipe, wire and<br />
cable, and conductive products.<br />
Arosperse 5-183a is a soft-beaded furnace black for<br />
use in semi-conductive insulation shields for mediumvoltage<br />
cables. With low sulphur impurities and low<br />
sieve residues, it is a very clean product.<br />
Another application is potable water pipe, which<br />
requires a clean, smooth conductive surface.<br />
Printex Zeta A is designed specially for pressure<br />
piping in gas and water distribution. The high chemical<br />
purity and physical cleanliness minimises taste and<br />
odour effects. Low compound moisture absorption and<br />
excellent microscopic dispersion performance ensure a<br />
smooth, defect-free pipe. It also gives the polymer<br />
excellent UV protection, shielding the pipe from<br />
photo-oxidative degradation. Printex HV is for use in<br />
high-voltage cables<br />
❙ www.orioncarbons.com<br />
Machinery & tooling<br />
Battenfeld-<br />
Cincinnati is a<br />
leader in<br />
large-diameter<br />
pipe extrusion<br />
Battenfeld-Cincinnati USA will present a variety<br />
of technologies at NPE, including co-extrusion options,<br />
high-tech pipe heads for multi-layer applications as<br />
well as twin screws with tailored wear resistance<br />
features.<br />
The parallel twin screw extruder TwinEx range has<br />
been expanded with the industry’s highest-output large<br />
diameter machine, the TwinEx 148-28. It was designed<br />
to meet the growing demand for large diameter PVC<br />
pipe extrusion and high-output profile extrusion in<br />
North America. It also has a Z design gearbox with the<br />
main motor in the back for easy maintenance and can<br />
process both virgin and regrind PVC with output rates of<br />
up to 2,000kg/h (4,400lbs/hr).<br />
The SolEx high-performance single screw extruder<br />
series yields high outputs with low melt temperatures<br />
and homogeneous melt for polyolefin materials. It has<br />
been extended with a new machine, the SolEx 150,<br />
which is particularly suited to the demands of the large<br />
diameter heavy wall PO pipe market. It offers outputs<br />
up to 2,750kg/h (6,000lbs/hr) for HDPE applications.<br />
s<br />
36<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
www.pipeandprofile.com
Oil & Gas Polymer<br />
Engineering Texas <strong>2015</strong><br />
Focused industry conference on qualifying and utilizing elastomers,<br />
thermoplastics, composites and coating materials in oilfield applications<br />
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NPE <strong>2015</strong><br />
| show preview<br />
The company will also show two examples of<br />
co-extrusion. The ConEx range from 38 to 63mm is<br />
suited to co-extruded pipe and profile applications.<br />
A ConEx 63 from the conical<br />
twin screw series will be<br />
seen in a co-extrusion<br />
set-up on a pedestal<br />
mount with 4-axis<br />
adjustment with the<br />
TwinEx 148-28. This<br />
configuration could be used for foam core,<br />
triple-walled pipe extrusion, PVC fence and siding.<br />
❙ www.battenfeld-cincinnati.com<br />
Beier America is introducing a new high throughput<br />
extruder for polyolefin pipe production. The BRD series<br />
of 38:1 L/D grooved feed throat extruders incorporates<br />
numerous innovative features, including: a feed throat<br />
with a large eccentric feed opening; large surface area,<br />
rectangular grooved feed channels; air gap heat<br />
insulation; and a spiral water cooling system.<br />
The result is high material conveying efficiency – regardless<br />
of back pressure – with low water consumption,<br />
says the company. A BRD60/38 pipe extruder will<br />
be exhibited at the NPE.<br />
The Beier BRD series is designed for efficient polymer<br />
processing with extrusion production pressures up to<br />
455bar. Newly designed components help to separate<br />
plasticising performance from back pressure. The BRD<br />
90/38 has an HDPE throughput rate of 1000kg/h.<br />
❙ www.beieramerica.com<br />
Extrunet America Inc is the North American subsidiary<br />
of a European specialist in energy efficient extrusion<br />
machinery. It claims up to 80% energy savings<br />
compared to conventional calibration tables – with<br />
positive side effects such as reduced noise, automated<br />
extrusion process control and innovative guillotine<br />
cutting technology.<br />
Central Vacuum Technology, as Extrunet calls its<br />
technology, has now been introduced to North America<br />
and more than 100 calibration tables have been<br />
upgraded – helping customers to reduce energy costs.<br />
Extrunet estimates that more than 1,000 profile<br />
downstream lines in North America are ‘coming of age’<br />
– reaching 20-25 years old. Its central vacuum<br />
technology can be retrofitted to most brands of<br />
calibration table.<br />
❙ www.extrunet.com<br />
tubing for the automotive, medical and industrial<br />
applications. The redesigned 800 series produces<br />
flawless extrusion and layer definition of fluoropolymer<br />
and other materials<br />
for fuel line constructions,<br />
multi-layer PEX pipe<br />
and drip irrigation. The<br />
design allows thin layer<br />
combinations of polymers and adhesives<br />
to 0.02mm or less.<br />
❙ www.guill.com<br />
Maillefer has developed a series of innovative<br />
ways of making holes in its PIL micro-drip irrigation<br />
hosing. The company opted for a mechanical drilling<br />
method driven by a high-performance motor in order to<br />
reach very high rates: its lines combine short drip<br />
emitter spacing and high extrusion line speeds, which<br />
translates to 2,000 holes per minute.<br />
Part of the challenge in drilling a hole in a fast-moving<br />
target is knowing where to aim, says Maillefer.<br />
“Our patent-pending emitter detection system helps<br />
us synchronise the movement with laser light precision,”<br />
it said. “Plus, with our auto-tuning algorithm, we<br />
zoom in onto the emitter pool zone quickly and simply.”<br />
❙ www.maillefer.net<br />
Tecnomatic of Italy has teamed up with Puma Plastic<br />
Solutions to bring its extrusion lines to the US. The two<br />
companies will participate at NPE,<br />
It will showcase its L/D 40 Zephyr 90 for pipe<br />
production – which has a throughput of up to 1,700kg/h<br />
– and of its Venus 400 die-head with <strong>Pipe</strong> Air Cooling.<br />
Zephyr boasts an array of technical solutions that is<br />
aimed at pipe producers that need more focused<br />
energy saving machines, with high output performance<br />
at lower melt temperatures. The innovation spans the<br />
entire extruder range and includes new spiral<br />
grooved bush, screw and motors.<br />
❙ www.tecnomaticsrl.net<br />
Guill Tool is<br />
introducing the<br />
latest generation<br />
of its<br />
Series 800<br />
extrusion<br />
tooling<br />
Beier America<br />
will exhibited a<br />
BRD60/38<br />
pipe<br />
extruder<br />
at NPE<br />
Guill Tool is introducing the latest generation of its<br />
Series 800, 2-to-6 layer extrusion tooling designed to<br />
produce high quality and material-efficient 0.125-6in OD<br />
www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 39
CONDUCTIVE<br />
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Developing technologies and applications for electrically and<br />
thermally conductive plastics<br />
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Materials | technology<br />
etps<br />
IPE introduces speciality products based<br />
on Solvay engineering thermoplastics<br />
International Polymer Engineering (IPE), a<br />
US-based custom extruder of thermoplastic<br />
tubing and profiles, has introduced a<br />
new range of products based on materials<br />
from Solvay Specialty Polymers.<br />
The products include high-precision<br />
microbore tubing, monofilaments and<br />
profiles, and are aimed at applications in<br />
the medical, aerospace, military and<br />
industrial sectors. IPE unveiled the new<br />
line at the Medical Design & Manufacturing<br />
(MD&M) West in February.<br />
IPE has seen growing demand for<br />
extrusions made of high-performance<br />
thermoplastics due to their ease of<br />
manufacturing and strong property<br />
profile. In particular, the company has<br />
seen a major shift toward replacing<br />
metals and thermoset materials with<br />
advanced thermoplastics in medical<br />
applications, according to Jonathan<br />
Jurgaitis, melt extrusion manager for IPE.<br />
“It’s clear that these high-performance<br />
materials have a strong track record, and<br />
the industry is familiar with them as a<br />
viable option for a range of applications,”<br />
he said. “IPE has worked closely with<br />
Solvay to develop custom products that<br />
meet the requirements of demanding<br />
end-use applications.”<br />
IPE chose Solvay’s sulfone polymers<br />
due to their high clarity, stiffness and<br />
steam sterilisability. Specifically, the<br />
company used Solvay’s Udel polysulfone<br />
(PSU) to fabricate 0.02in (0.5mm) monofilaments,<br />
and Radel polyphenylsulfone<br />
(PPSU) to make 0.06in (1.5mm) and 0.11in<br />
(2.8mm) monofilaments. It also used<br />
Radel PPSU to make 0.50in (12.7mm)<br />
microbore tubing with outer diameter (OD)<br />
of 0.012in and inner diameter (ID) of<br />
0.010in (0.3mm OD x 0.25mm ID).<br />
IPE has also used other Solvay grades.<br />
For example, it fabricates microtubes<br />
from KetaSpire Peek resin that deliver<br />
greater strength and rigidity than PTFE<br />
microtubes, and are easier to work with<br />
compared to those made of stainless<br />
steel. These microtubes are used in<br />
medical applications such catheters,<br />
endoscopic working channels, and<br />
laparoscopic instruments.<br />
At the same time, it uses AvaSpire<br />
Paek to extrude 0.06in (1.5mm) monofilaments,<br />
and Torlon polyamide-imide (PAI)<br />
for 0.06in (1.5mm) monofilaments. PAI<br />
offers the highest strength and stiffness<br />
of any thermoplastic up to 275°C (527F),<br />
says the company.<br />
Other monofilaments are made from<br />
PrimoSpire self-reinforced polyphenylene<br />
(SRP), while Halar ECTFE – a partially<br />
fluorinated, melt-processable polymer –<br />
is specified by IPE for 0.06in (1.5mm)<br />
monofilaments due to its high chemical<br />
resistance and lubricity.<br />
❙ www.ipeweb.com<br />
❙ www.solvayspecialtypolymers.com<br />
PBT<br />
Flame-retardant grades for optical fibre jackets<br />
free.<br />
Strict fire safety regulations<br />
for cable material are<br />
increasingly the norm in calls<br />
Evonik’s Vestodur grade for<br />
optical fibre jackets features<br />
excellent flame-retardant<br />
properties, yet is halogenfor<br />
tenders for public construction<br />
projects. This new<br />
halogen-free grade of<br />
polybutylene terephthalate<br />
(PBT) for optical fibre jackets<br />
and wire bundles has high<br />
flame-retardant properties,<br />
says the company.<br />
Vestordur X9426 has a high<br />
limiting oxygen index (LOI) and<br />
low smoke density, and any<br />
smoke gases emitted are of<br />
low toxicity. The extruded<br />
material is also extremely<br />
flexible, kink- and crushresistant<br />
and has good<br />
hydrolysis properties.<br />
Evonik offers a range of<br />
Vestodur PBT and Vestamid<br />
polyamide 12 compounds for<br />
cable extrusion. These are<br />
used both for the safe and<br />
efficient protection of optical<br />
fibres and for wire insulation<br />
and cable protection tubing.<br />
The latest development in PA<br />
12 is a material that meets<br />
the stringent HL3 requirements<br />
for rail vehicles in<br />
accordance with standard EN<br />
45545 – 2:2013.<br />
❙ www.vestodur.com<br />
www.pipeandprofile.com <strong>March</strong> <strong>2015</strong> | PIPE & PROFILE EXTRUSION 41
technology | Machinery<br />
MEASUREMENT<br />
Diameter gauges make 2,500<br />
measurements per second<br />
CONTROL<br />
Easy-to-use extrusion controllers<br />
West Control Solutions has<br />
introduced the PlastX family<br />
of temperature controllers for<br />
plastics and rubber extrusion.<br />
An easy-to-use menu<br />
features pre-populated setup<br />
fields with default parameters<br />
for plastic applications.<br />
This, together with the<br />
removal of unnecessary<br />
options, ensures that<br />
configuration is straightforward<br />
and fast to<br />
implement, says West.<br />
The controllers provide<br />
both ‘heat only’ and ‘heat/<br />
cool’ control in the same<br />
instrument. Units can be<br />
quickly converted to process<br />
indicators, reducing the need<br />
to stock multiple products for<br />
Sikora says that its Laser<br />
Series 6000 diameter<br />
gauges are designed for<br />
customer requirements<br />
that exceed the classic<br />
demands for quality<br />
control in the hose and<br />
tube industry.<br />
The device makes 2,500 measurements<br />
per second, with high single<br />
value precision, allowing for optimum<br />
line control and reliable statistical<br />
data. Sikora offers three gauge head<br />
models for product diameters from 0.2<br />
to 78mm. The Series 6000 can also<br />
handle transparent products.<br />
The devices include an integrated<br />
LCD display with control panel, which<br />
provides the operator with diameter<br />
values at a glance, directly at the<br />
measuring device. At the control<br />
extrusion applications.<br />
PlastX controllers are<br />
available in a compact 1/16 DIN<br />
size (48 x 48mm) and 1/8 DIN<br />
size (48 x 96mm). Standard features<br />
include process and loop<br />
alarms, with LED indicators<br />
for the band and low alarms.<br />
An LED indicator is also<br />
present during auto-tuning.<br />
The controller has one<br />
panel the diameter nominal value can<br />
be entered and the control module<br />
activated. By way of line speed or<br />
extruder rpm, the module automatically<br />
controls the diameter to the<br />
specified value. The high measuring<br />
rate of the diameter devices also<br />
allows the detection of lumps and<br />
neckdowns.<br />
A universal interface module is<br />
directly integrated in the gauge heads<br />
for all connections, such as RS 485, RS<br />
232 and Profibus-DP, or industrial field<br />
buses such as CANopen, Ethernet/IP,<br />
DeviceNet and Profinet IO.<br />
It also has an optional Wi-Fi<br />
interface, which allows a direct<br />
connection to a smartphone or laptop<br />
for diagnostic and quality control<br />
purposes.<br />
❙ www.sikora.net<br />
universal input, multiple<br />
output configurations and<br />
optional Modbus RS485<br />
communications.<br />
❙ www.west-cs.com<br />
TUBE PRODUCTION<br />
Flexible<br />
production<br />
of PBL tube<br />
Breyer has adapted its Topline<br />
and Ecoline tube extrusion<br />
systems to allow flexible, cost<br />
effective production of<br />
cosmetic tubing.<br />
Plastic barrier laminate<br />
(PBL) tubes are made from a<br />
web laminate and have a<br />
visible side seam, in production<br />
runs typically above<br />
100,000 tubes per order.<br />
Laminate film is supplied to<br />
the tube manufacturer. High<br />
speed film lines, side-seamers<br />
and printers allow<br />
economic mass production of<br />
such film but the individual<br />
design for small orders is<br />
often not economical.<br />
Breyer has developed a<br />
special solution for this,<br />
based on its experience of<br />
extrusion systems for flat<br />
film and extruded tubes.<br />
The extrusion line, with a<br />
working width of 1600mm,<br />
800mm, 400mm or less,<br />
allows the production of<br />
slitted flat film with a flexible<br />
configuration of different<br />
layers for different tube<br />
diameters and lengths.<br />
EVOH, PA, PET and COC<br />
barrier layers are all<br />
possible, says Breyer.<br />
Properties like colour and<br />
haptics, which are very<br />
important for the first<br />
impression of the tube<br />
product, can be easily<br />
adapted by using different<br />
polymers such as PET, PP,<br />
PA or PE. An isolated inner<br />
layer even allows the usage<br />
of recycled material.<br />
❙ www.breyer-extr.com<br />
42<br />
PIPE & PROFILE EXTRUSION | <strong>March</strong> <strong>2015</strong><br />
www.pipeandprofile.com
CORRUGATED PLASTIC PIPE<br />
TECHNOLOGY<br />
R<br />
This month’s free<br />
brochure downloads<br />
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Battenfeld-Cincinnati: twinEX<br />
Sica: downstream equipment<br />
twinEX<br />
The new dimension<br />
in parallel twin screw extruders<br />
This eight-page technical<br />
brochure from Battenfeld-<br />
Cincinnati covers its twinEX<br />
parallel twin-screw<br />
extruders which are ideally<br />
suited for the production of<br />
PVC pipe, profile and sheet<br />
with outputs ranging from<br />
115 to 2,500 kg/hour.<br />
This brochure from Sica<br />
covers the company’s wide<br />
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Maguire: gravimetric blenders<br />
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This interactive product<br />
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PlasMec: PVC mixing/cooling<br />
This brochure covers<br />
PlasMec’s HEC High<br />
Efficiency Horizontal Cooler<br />
for the production of rigid or<br />
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Available in sizes up to 8,000<br />
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Global conference on the PVC industry, compounding, recipes and market trends<br />
PVC Formulation <strong>2015</strong> is<br />
taking place on 16-18 <strong>March</strong><br />
in Cologne, Germany. This<br />
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AMI Strategy Seminars<br />
THE GLOBAL PLASTICS<br />
INDUSTRY SEMINAR<br />
<strong>2015</strong><br />
A strategic review of the prospects<br />
for the global plastics industry<br />
<strong>2015</strong> seminar dates and locations<br />
9th April <strong>2015</strong> Bristol UK<br />
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Plastics Industry Seminars<br />
in <strong>2015</strong> with dates set for<br />
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brochure has all the details.<br />
14th April <strong>2015</strong> Cologne Germany<br />
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16-18 <strong>March</strong> <strong>2015</strong><br />
Maritim Hotel,<br />
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Plastic <strong>Pipe</strong>s in Infrastructure<br />
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Plastic <strong>Pipe</strong>s <strong>2015</strong><br />
in Infrastructure<br />
Trends & developments in design, production, installation and exploitation<br />
of plastic pipes systems for infrastructure<br />
14-16 April <strong>2015</strong><br />
Millennium Gloucester Hotel,<br />
London, United Kingdom<br />
AMI’s third international<br />
conference on plastics pipes<br />
for infrastructure applications<br />
will be held in London<br />
on 14-16 April <strong>2015</strong>.<br />
Download the programme<br />
which covers the latest<br />
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PolymerFoam<strong>2015</strong><br />
International conference on foam technology and applications in thermoplastic<br />
and elastomeric products<br />
April 14-15, <strong>2015</strong><br />
Renaissance Newark Airport Hotel,<br />
Newark, New Jersey, USA<br />
AMI’s international conference<br />
on thermoplastic and<br />
elastomeric foam technologies<br />
and applications is<br />
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Compounding World Congress<br />
Fire Retardants in Plastics<br />
Congress <strong>2015</strong><br />
The international conference on business strategies, innovative additives and<br />
process optimisation for thermoplastics compounders<br />
18-20 21-23 February April <strong>2015</strong> 2013<br />
Austria Maritim Trend Hotel Hotel, Savoyen,<br />
Cologne, Vienna, Austria Germany<br />
Following the considerable<br />
success of the Compounding<br />
World Forum in the USA,<br />
Compounding World<br />
magazine and AMI are<br />
launching this new event in<br />
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features a selection of the<br />
industry’s most influential<br />
leaders.<br />
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FIRE RETARDANTS<br />
IN PLASTICS <strong>2015</strong><br />
Trends and technical developments in the international flame retardant industry<br />
May 12-13, <strong>2015</strong><br />
Grand Hyatt Denver,<br />
Denver, Colorado, USA<br />
5<br />
2<br />
Covering market trends and<br />
technical developments in<br />
the international flame<br />
retardant industry, AMI’s<br />
Fire Retardants in Plastics<br />
conference returns to<br />
Denver, Colorado, USA on<br />
12-13 May. Download the<br />
programme here.<br />
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Polymer Sourcing & Distribution<br />
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POLYMER SOURCING<br />
& DISTRIBUTION <strong>2015</strong><br />
A new era for the polymer supply chain<br />
HEADLINE SPONSOR<br />
18-20 May <strong>2015</strong><br />
Marriott Hotel,<br />
Hamburg, Germany<br />
AMI’s 11th conference on<br />
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Germany on 18-20 May<br />
<strong>2015</strong>. The programme<br />
covers developments in<br />
polymer distribution and<br />
includes analysis of polymer<br />
supply and demand trends.<br />
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Taking place on 9-10 June<br />
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International business and technology conference for the window,<br />
door, decking, fence and siding profile industry<br />
June 9-10, <strong>2015</strong><br />
Hilton Philadelphia City Avenue,<br />
Philadelphia, Pennsylvania, USA<br />
SPECIAL OFFER: Save $300 if you register before <strong>March</strong> 6, <strong>2015</strong><br />
AMI’s 14th international<br />
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MASTERBATCH<br />
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Connecting with downstream customers<br />
9-11 June <strong>2015</strong><br />
Maritim Hotel,<br />
Cologne, Germany<br />
The 28th edition of AMI’s<br />
Masterbatch conference is<br />
being held on 9-11 June<br />
<strong>2015</strong> in Cologne, Germany.<br />
This year’s programme<br />
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Lego, PepsiCo and Microsoft.<br />
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Polymers in Cables<br />
Conductive Plastics<br />
Polymers in Cables<br />
<strong>2015</strong><br />
The international conference and exhibition for polymers in cable applications<br />
June 23-24, <strong>2015</strong><br />
Hilton Philadelphia City Avenue,<br />
Philadelphia, Pennsylvania, USA<br />
The American version of<br />
AMI’s conference on<br />
Polymers in Cables applications<br />
is being held in<br />
Philadelphia, PA, USA on<br />
23-24 June. Check out the<br />
programme which covers<br />
interesting materials and<br />
application developments.<br />
CONDUCTIVE<br />
PLASTIC S 2O 15<br />
Developing technologies and applications for electrically and<br />
thermally conductive plastics<br />
29th June – 1st July <strong>2015</strong><br />
Hotel Nikko,<br />
Düsseldorf, Germany<br />
This new conference from<br />
AMI covers thermally- and<br />
electrically-conductive<br />
thermoplastics, examining<br />
materials technology<br />
developments as well as<br />
emerging market opportunities.<br />
It takes place in<br />
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June to 1 July.<br />
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extruder of the month<br />
Tubi<br />
Head office: Paddington, NSW, Australia<br />
CEO:<br />
Founded:<br />
Ownership:<br />
<strong>Profile</strong>:<br />
Product lines:<br />
Factory locations:<br />
Other information:<br />
Marcello Russo<br />
1976 (as Ravcoplast)<br />
Private<br />
Tubi began in Australia in 1976 as Ravcoplast, developing pressure and nonpressure<br />
pipe in HDPE and PVC, as well as extruded film. However, the company<br />
sold its interests in conventional pipe in 2009, and began producing a range of pipe<br />
using its own patented system – the Mobile Modular Extrusion Plant, which allows<br />
production of HDPE pipe in the field.<br />
Using its mobile production units, the company produces a range of pipe, including<br />
conventional HDPE, pressure HDPE (up to 40bar) and corrugated HDPE. The way in<br />
which the pipe is produced helps to the cost of pipe transportation, and guarantees<br />
supply – as the plant is situated at the construction site. The fact that pipe is<br />
produced directly on site means that it can be produced in a single length – reducing<br />
conventional weld joints by around 95%.<br />
The company’s headquarters are in Paddington, in New South Wales, but pipe<br />
production takes place all over the world – wherever the company’s mobile units are<br />
located. It recently commissioned its first Tubi 630 modular mobile plant to make<br />
pipe from 90 to 630mm diameter.<br />
Other Tubi in-house technologies, such as Quick-String, allows large bore reeling<br />
and deployment of up to 4000m of portable pipe, with diameters up to 1200mm.<br />
To be considered for ‘Extruder of the Month’, contact the editor on lou@pipeandprofile.com<br />
Forthcoming features<br />
The next issues of <strong>Pipe</strong> and <strong>Profile</strong> Extrusion magazine will have special reports on the following topics:<br />
April <strong>2015</strong><br />
Control & instrumentation<br />
Laboratory extruders<br />
Computer modelling software<br />
Plast preview issue<br />
May <strong>2015</strong><br />
PVC recycling<br />
<strong>Profile</strong> die developments<br />
Plastic <strong>Pipe</strong>s in Infrastructure report<br />
Chinaplas preview issue<br />
Editorial submissions should be sent to Lou Reade: lou@pipeandprofile.com<br />
For information on advertising in these issues, please contact<br />
Claire Bishop: claire@amimagazines.com Tel: +44 (0) 1732 605976
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<strong>Pipe</strong> and <strong>Profile</strong> - Jan/Feb<br />
The January/February <strong>2015</strong><br />
edition of <strong>Pipe</strong> and <strong>Profile</strong><br />
Extrusion looks at the latest<br />
developments in<br />
screenchangers, trends in the<br />
titanium dioxide market, and<br />
innovation in ETP and<br />
composite pipe.<br />
➤ Click here to view<br />
<strong>Pipe</strong> and <strong>Profile</strong> - Nov/Dec<br />
The November/December<br />
edition visits AMI’s WPCs<br />
conference to find out about the<br />
latest market and technology<br />
trends. Plus, a novel application<br />
for PEX pipe in a US ski resort<br />
and the latest innovations in<br />
materials handling and pipe<br />
joint inspection.<br />
➤ Click here to view<br />
Compounding World – Feb<br />
Compounding World’s February<br />
issue is packed with articles on<br />
thermally conductive plastics,<br />
extrusion simulation software,<br />
new machinery on show at<br />
NPE, materials handling<br />
systems, and the return of<br />
aliphatic polyketones.<br />
➤ Click here to view<br />
<strong>Pipe</strong>line Coating – Feb<br />
The February edition of<br />
<strong>Pipe</strong>line Coating takes an in<br />
depth look at investment in the<br />
African pipeline industry. Plus<br />
the latest oil and gas market<br />
outlook, offshore lining<br />
technology and smart coating<br />
developments.<br />
➤ Click here to view<br />
Injection World – Jan/Feb<br />
This edition of Injection World<br />
magazine is packed full of<br />
features on thin-wall<br />
moulding, thermoplastic<br />
composites, modelling<br />
software, smart factories and<br />
European market trends. Plus<br />
there’s a focused preview of<br />
NPE.<br />
➤ Click here to view<br />
Film and Sheet – Jan/Feb<br />
This edition of Film and Sheet<br />
Extrusion includes reports on<br />
developments in bioplastics,<br />
materials testing technologies,<br />
and new polyolefin grades and<br />
applications. Plus there is a<br />
preview of the NPE <strong>2015</strong><br />
exhibition.<br />
➤ Click here to view<br />
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dates for your diary<br />
Global exhibition guide <strong>2015</strong><br />
10-14 <strong>March</strong> Koplas, Seoul, South Korea www.koplas.com<br />
12-14 <strong>March</strong> 3P Plas Print Pack, Lahore, Pakistan www.plasprintpack.com.pk<br />
23-27 <strong>March</strong> NPE, Orlando, FL, USA www.npe.org<br />
26-28 <strong>March</strong> Eurostampi & Plastixexpo, Parma, Italy www.mecspe.com<br />
2-5 April IPAF, Istanbul, Turkey www.ipaffuarlari.com<br />
8-10 April Plastic Japan, Tokyo, Japan www.plas.jp/en<br />
21-24 April Elmia Polymer, Jönköping, Sweden www.elmia.se/en/polymer<br />
4-8 May Feiplastic, Sao Paulo, Brazil www.feiplastic.com.br<br />
5-9 May Plast, Milan, Italy www.plastonline.org/en<br />
7-9 May PPP Africa, Nairobi, Kenya www.expogr.com<br />
20-23 May Chinaplas, Guangzhou, China www.chinaplasonline.com<br />
23-25 May PPP Africa, Tanzania www.expogr.com<br />
16-17 June PDM & PRE, Telford, UK www.pdmevent.com<br />
16-18 June Plast-Ex, Toronto, Canada www.plast-ex.org<br />
9-12 July Interplas Thailand, Bangkok, Thailand www.interplasthailand.com<br />
26-29 August T-Plas / Tiprex, Bangkok, Thailand www.tplas.com<br />
1-3 September Plasti & Pack, Lahore, Pakistan www.plastipacpakistan.com<br />
22-24 September Composites Europe, Dusseldorf, Germany www.composites-europe.com<br />
13-17 October Fakuma, Friedrichshafen, Germany www.fakuma-messe.de<br />
20-22 October Plastex Uzbekistan, Tashkent www.plastex-events.com<br />
AMI conferences for pipe & profile extruders<br />
3-5 <strong>March</strong> <strong>2015</strong> Cables, Cologne, Germany<br />
16-18 <strong>March</strong> <strong>2015</strong> PVC Formulation, Cologne, Germany<br />
14-16 April <strong>2015</strong> Plastic <strong>Pipe</strong>s in Infrastructure, London, UK<br />
21-23 April <strong>2015</strong> Compounding World Congress, Cologne, Germany<br />
9-10 June <strong>2015</strong> <strong>Profile</strong>s, Philadelphia, USA<br />
9-11 June <strong>2015</strong> Masterbatch, Cologne, Germany<br />
23-24 June <strong>2015</strong> Polymers in Cables, Philadelphia, USA<br />
15-16 September <strong>2015</strong> Medical Grade Polymers, Boston, USA<br />
For information<br />
on all these events<br />
and other conferences on<br />
film, sheet, pipe and<br />
packaging applications, see<br />
www.amiplastics.com<br />
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