PLASTICS - INDIAN SCENARIO

Ranked 8th in the world in Plastic Consumption.

Per Capita consumption of 6 Kg compare to 27 Kg of world.

Expected to be 3rd largest consumer of plastic after US & China by 2010.

Raw Material producers - 15 Nos.

Total No. of processing unit - 30,000 approx.

Total No. of Machines - 58,811 approx.

Total No. of Extrusion Machines - 19,000 approx.

PLASTIC PROCESSING TECHNOLOGY

EXTRUSION – Pipes, Profiles, Films, Wire Coating etc.

INJECTION MOLDING – Crates, Furniture, Electrical Comp., etc.

BLOW MOLDING – Bottles, Cans, Containers etc.

OTHERS – Thermoforming, Compression, Rotational etc.

SHARE BY PROCESSING SEGMENT

Extrusion - 66%

Injection Molding - 20%

Blow Molding - 06%

Others - 03%

Hand Operated - 05%

OVERVIEW ON EXTRUSION TECHNOLOGY OF

PIPE

• PVC

• CPVC

• 3 – LAYER FOAM CORE

• HDPE

• PPR

GENERAL ARRANGEMENT OF PVC PIPE PLANTGENERAL ARRANGEMENT OF PVC PIPE PLANT

EXTRUDER

DIE HEAD

VACUUM TANKSPRAY TANKHAUL-OFFCUTTERTRIPPING

EXTRUDER

DIE HEAD

(WITH TROLLEY)

VACUUM TANK

SPRAY TANK

HAUL-OFFCUTTER

COMPARISON BETWEEN SINGLE & TWIN SCREW EXTRUDERS

SINGLE SCREW TWIN SCREW

OUTPUT LOW HIGH

POWER CONSUMPTION HIGH LOW

FORMULATION COST HIGH LOW

SHEAR RATE HIGH LOW

MIXING POOR VERY GOOD

COST LOW HIGH

ECONOMIC VIABILITY VERY POOR VERY GOOD

TWIN SCREW EXTRUDER MODEL

Conventional Version V Model Push Button Type

Latest Version V4 Model Smart Touch Type

SCREW TEMPERATURE CONTROL SYSTEM SCREW TEMPERATURE CONTROL SYSTEM

• Works on the principle of the heat exchanger tube, improving heat exchange between the various zones of the screw. • Distilled water is used as the temperature control medium.• It evaporates in the high temperature section of the screw and releases the energy absorbed by condensing in the low temperature section.• Lower energy consumption & absolutely no maintenance.

Vertical Feeder - allows under-filling, complete filling or forced feeding of material into the screw.a whole range of marketable formulation can be processed having different

bulk densities with just one screw geometry. enables the extruder rate to be raised even with low bulk densities.lowers the screw speed while keeping output constant and thereby reducing

wear.

VERTICAL FEEDER VS. HORIZONTAL FEEDERVERTICAL FEEDER VS. HORIZONTAL FEEDER

VERTICAL(CRAMMER) HORIZONTAL

Barrel

Free fall of PVC compound

Feeder screw Drive

SINGLE SPIDER DIE

• Ideal dwell time profile over the whole flow cross-section.

• Homogeneous melt distribution with selective temperature control.

• Facilitates high output.

SINGLE SPIDER

DOUBLE SPIDER DIE HEAD - RD SERIES

DOUBLE SPIDER

• Elimination of spider lines due to staggered double Decker spider.

• Improved mechanical properties.

• Processing of thick wall pipes without spider lines.

• Excellent wall thickness control at higher throughput rate.

ACCOUNTANCY

WIDER PIPE DIAMETER RANGE

75 / 250 : 20D – 75D

110 / 250 : 63D – 110D

200 / 400 : 63D – 200D

250 / 600 : 90D – 250D

315 / 800 : 110D – 315D

400 / 800 : 110D – 400D

450 / 1000 : 160D – 450D

RD – 1 : 20D – 110D(725 Kg/Hr.)

RD – 2 : 63D – 280D(910 Kg/Hr.)

RD – 3 : 160D – 450D(1500 Kg/Hr.)

EXISTING DIE HEAD NEW RD SERIES DIE HEAD

CALIBRATION Calibration is required to form the pipe.

Pipe outside dia is sized in sizer unit.

Two methods for sizing calibration.

(Pressure calibration & Vacuum calibration)

PRESSURE CALIBRATION (Spray Tank K Type)

Floating bunk with help of chain is to be inserted in pipe after pressure

calibration sleeve.

Compressed air is supplied through die between floating bunk & die.

Pipe is formed by internal air pressure 0.5 bar air pressure is given.

Pipe is cooled by closed water spraying thr’u nozzle at 2.5 bar.

Vacuum regulator system

Water Sump

Spray Pump

Vacuum Pump

Double Filter Unit

VACUUM CALIBRATION (Vacuum Tank V Type)

Pipe is welded with lead pipe is pulled by haul off & vacuum is

applied in vacuum tank to form the pipe .

Pipe is sized in vacuum calibration sleeve.

200 to 400 mm of Hg vacuum is kept .

Pipe is cooled by close water spraying thr’u nozzle at 2.5 Bar

MULTIBELT HAUL-OFF

For higher dia pipe pulling force required is more, so multibelt haul-off is recommended. It also ensures roundness of the pipe.

4 Belts 50% force required than 2 belts.

6 Belts 30% force required than 2 belts

So in multibelt haul-off dimensional control is better.

HAUL-OFF

2-BELT HAUL-OFF

Two types of cutter:-

1. SPR type cutter (upstroke),(up to 200Ø, Upgraded to new model 225Ø,250Ø)

- Extended bed cutter for smaller diameter pipes with higher line speed.

2. SU type cutter (planetary), (up to 630Ø)

- Flush mounted saw is provided for smaller OD pipes.

- Planetary saw is provided for larger OD pipes.

- Thicker as well as thinner pipes can be cut without Burrs.

- Chamfering on one or both sides is possible with adjustable chamfer size.

SU-CUTTER SPR-CUTTER

DUAL STRAND EXTRUSIONDUAL STRAND EXTRUSION

Dual stand extrusion lines are advantageous when higher throughputs are to be achieved even with Smaller & thinner pipes.

Dual strand extrusion allows almost100% utilization of extruder capacity for small & thinner Pipes, which is otherwise not possible in single lines.

Different diameters can be produced simultaneously On dual strand lines.

Dual strand line offers an impressive Price/performance ratio.

CPVC PIPES

•Ideally suited for self supporting constructions as plumbing pipes.

•Ideally suited for transporting hot & cold water in residential complex, hotels, hospitals, etc.

•Also approved for potable water.

•Used in industrial piping too.

CPVC PIPES

SPECIAL FEATURES OF CPVC PLANT:

•HIGHER TORQUE GEAR BOX

•HIGH CAPACITY MOTOR

•TRIPLE PLATING SCREWS

•STAINLESS STEEL CONNECTING HEAD

•STAINLESS STEEL DIE HEAD

•STAINLESS STEEL DIES

•STAINLESS STEEL VACUUM TANK

PRODUCTION OF PVC-U FOAM CORE PIPESPRODUCTION OF PVC-U FOAM CORE PIPES3 LAYER PIPE3 LAYER PIPE

APPLICATIONSAPPLICATIONS : :

At present foam core pipes are used only for non-pressure applications such as drainage sewage and ventilation pipes. In addition, they are used for cable protection.

ADVANTAGES OF 3-LAYER FOAM CORE PIPE :

Lower thermal conductivity (insulating effect). Weight/ meter reduces. Lower costs per meter length.

ADVANTAGES OF 3-LAYER COMPACT PIPES :

Saving of material costs by using recycled material in the middle layer.

Possibility to use different PVC formulations (increased pipe quality).

3-layer increase the stress specification (sandwich). 3-layer can minimize the effects of inclusions.

LAYER THICKNESS DISTRIBUTION

The minimum thickness of the inner and outer layer depends on the pipe size. The tolerance for overall pipe dimension correspond to the specification of the din standards.

10-25INNER

60-80MIDDLE

10-15OUTER

% OF TOTAL WALLTHICKNESS

LAYER

HDPE PIPES

ADVANTAGES OVER PVC1. Very high impact strength

2. Light weight

3. Flexibility and Ductility

4. Chemical resistance

5. Weatherability

6. Smooth internal surfaceAPPLICATIONS:• Industries 11. Power generation• Agricultural irrigation 12. Pulp and paper• Optical fiber cable conduits 13. Sewage• Chemical 14. Potable water supply• Dredging 15. Submarine pipelines• Fertilizers 16. Corrosive wastage• Domestic gas distribution 17. Drainage lines• Landfill reclamation 18. Relining salt water intakes• Mining• Oil and gas production

7. Resistance to rodent attack

8. Corrosion-Resistant

9. Inert

10.Non Toxic

11. Long Lasting

12. Terrain Following

Single Screw Extruder

Automatic Hopper Loader

Hopper

Heating Panel

Plug Socket For Die Head

Barrel Cooling Blower

Single Screw

Smart Touch

GROOVED FEED BUSH:

For the extrusion of polyolefin pipes, single screw extruders are equipped with grooved feed bush.

In combination with barrier screw, these extruder achieve high plastification rates whilst delivering and excellent melt homogeneity.

Main flight

Discharge zone Barrier zone Feed zone

Trailing edgeSolid bed Melt reservoir

Leading edge

Cylinder

Solid channel Barrier flight

Melt flight

PRINCIPLE OF THE BARRIER SCREW

• Due to separate melt & solid channels, less heat is required to get good melt quality

• Due to this, processing at lesser melt temperature is possible

• Higher throughput rates without compromise on melt quality

• Improved melt homogeneity.

• Better physical properties

• Wide range of material can be processed in same screw

• Reduced power consumption on account of less melt temperature & less motor power

ADVANTAGES OF BARRIER SCREWADVANTAGES OF BARRIER SCREW

LATTICE BASKET DIE HEAD (SI)

Low pressure build-up and low melt temperature, even with high throughput.

Good homogenization due to double diversion of the melt.

Constant processing characteristics over the full range of materials.

Consistent product quality for all pipe sizes.

Faster assembly lesser maintenance due to lesser components.

Even distribution of material.

Ideal for thin walled pipes.

SPIRAL MANDREL DIE HEAD

SPIRAL LATTICE BASKET DIE HEAD (VSi)

Consists of spiral for coarse distribution and a compact lattice for fine distribution of melt.Large processing window.Low pressure requirement.Excellent wall thickness distribution.

JOCKEY EXTRUDER

19mm JOCKEY EXTD.

30mm JOCKEY EXTD.

• It endures to heat and high climatic temperatures.• It reserves its original form, flexibility and chemical properties at high

temperatures.• It is resistant to chemical reactions, acids salt and alkali, may safely

be used together.• It has resistance to corrosion, it does not rust or decay.• The friction calcification is very low, the surface is clean and smooth

and it will not hold other particles to fill in cavities.• There is no isolation against heat. It is resistance to extreme heat/cold

and will not deform or give in between –20 °C to +90°C environmental temperatures.

• It is extremely light, therefore easy to transport and install.• It is resistant to ultra violet rays. (Black color type)• The operational pressure resistance is 20 ATU at 20°C and 10 ATU at

65°C.• It is resistant to long term hot water transmission and under normal

environmental condition it endures operational heat 70°C – 90°C

FEATURES:-