2008-07-11 Manufacturing News

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Innovative PVC foam core pipe extrusion line delivers impressive performance

KraussMaffei Berstorff complete extrusion line for PVC foam core pipe to reduce raw material consumption and or costs while maintaining highest pipe quality.

Raw material costs can account for as much as 90% of the manufacturing cost of plastic pipe. Targeting the cost-saving potential in this area, KraussMaffei Berstorff has made it a high priority to develop machines and systems that will reduce raw material consumption and/or costs while maintaining highest pipe quality. KMB’s foam-core pipehead series is a good example. On June 19, 2008, over 70 customers gathered at KraussMaffei’s Munich plant for one of the company’s in-house Spotlight events. These events focus on a single machine or production challenge. This time, the spotlight was on a complete PVC foam-core pipe extrusion line in action.

KraussMaffei Berstorff supplied this complete extrusion line for PVC foam-core pipe. View High resolution image. photo: KraussMaffei Berstorff

Innovation and high performance for profitability
Before the demonstration, Daniel Lachhammer, KraussMaffei Berstorff Product Manager Pipe Extrusion, gave a brief talk on the company’s engineering concept for PVC foam core extrusion. Dr. Udo Anders, Technical Product Manager at Baerlocher GmbH, brought the experience and global expertise of an international lead supplier of plastics additives to bear in a talk on stabilization, extrusion and development trends in foam-core pipe. The visitors then moved on to the demonstration in the KraussMaffei Berstorff test lab. Headed by two twin screw extruders (KMD 90-36 B/R and KMD 75-36 B/R) plus a completely reengineered multilayer pipehead (KM 3 LRK 43), the line produced PVC foamcore pipe with 400 millimetre diameter and 11.7 millimetre wall thickness at a rate of 900 to 1000 kilograms per hour. Foaming reduces the density of the pipe’s core layer to as little as 0.6 kilogram per cubic decimetre. This has the effect of reducing the total density of the 3-layer pipe by up to 30% – with proportionate savings in material costs. A typical application for PVC foam-core pipe is pressureless wastewater pipe.

The Spotlight event reinforced KMB’s reputation for strength in innovative engineering. Seeing the pipe line in action left the visitors with a powerful impression of its performance and potential for cost saving – prompting a flow of requests for quotations for specific systems.

Complete, single-vendor solution
The line was supplied complete with all downstream components including the socketing machine and palletizing unit. This specific extrusion line is part of a turnkey project for a Russian customer.

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