HDPEPI

PEPROCESS

HDPEalsok nownhi
ghde ns
itypo
lyethyl
eneandmadeu pfromp ol
yethyl
enewhichmakes
l
argestfami l
yofpolymer.I
tisverygoodther
malandme chani
calprope
rtie
swhichmakes
wi
de l
yselectedmateri
alsi
nmakingofdifferentp
roduct
.Co mpres
sivetens
ilest
rengt
hand
st
iffnessisveryhi
ghinHDPEp olymersal
ongsi
dewit
hhighme l
tingandgr eat
cr
ystall
iza
t i
onpoi
nt.

Toproducehighqual
it
ypi
pes,highdens
itypol
yet
hyl
enep l
ast
icsar
econsi
dere
dgoodi
n
pl
asti
cindustri
es.
HDPEp i
pesar ec
orro
sivefr
eeandfle
xibl
etoworkwit
h,whi
chmakes
pi
pesmo r
ehandyanddu r
able.HDPEp i
pemadeareli
ghtwei
ghtandcons
umesles
sene
rgy
whi
lemanu fact
uri
ng.

Thep ro
c es
singtemperatu
r eforHDPEi ngene
ralis160°
C-2 5
0°Candshr
inkagerateis
cons
ider e
d1 .5%-3%.Highhe atwit
hs t
andabil
it
y,flex
ibi
li
tyandmachi
nabil
itymakesHDPE
asleadingpo l
ymerinmakingv ar
ieti
esofpl
asti
cp ro
ducts.
Theprodu
ctsl
ikepipes
,
detergentbo tt
les
,andautomo bi
lepart
saremadefr omHDPEp ol
ymer.

Equi
pmentUs
ed

 Ex
tru
derCo
ntr
oll
er

 Di
e

 Co
mpr
ess
or

 Mo
tor

 Ro
ll
er

 HDPEr
esi
n

 Si
x-me
terwat
erbat
htu
bfo
rco
oli
ngand

 Au
tomat
icp
ipec
utt
er

Ex
truder

Extrude risawi der angep roduct

ionmachineu s
edi nmanu fact
uringv ar
iet
iesofproducts
.
Theex t
r udersge nerall
yconsis
toffe edhop pe
r,ahe atingbarrel
,screwanddie.Screw
consi
stso ffi v
ehe atingzonechannel
s,throughwhic hrawmat eri
alsismelt
e di
nsi
det i
lli
tis
homoge ne o
usins tate.Whenme l
tmi x
turere ac
hest hedi e
,therequiredproduc
twillbe
produced. Thev ar i
etiesofdiegivemanydi fferentt ypeofproduct;howeverhopp
e r,
screw,
barrelre mainst hesamei nmanu factur
ingp ro
cess.
FeedHo
pper

Feedisconsi
deredamo uthoftheextr
u der;alltherawmat er
ial
sar efirstpou redi
nfeed
wheretheyarep re-heated.Al
ltherawmat erialspassthroughfee dthr o
ats mo o
thl
yand
reachtheheati
ngbar relforfurthe
rpr oces
s.Mat eri
almu streacht otheo t
he rendofthe
barrels
tart
ingfr omfe edhopperoral
soc all
edfe edingzone.Supplyo ffe e
di nthehopper
shou
ldbes u
fficienttocr e
aterequi
redp ress
u retoco nt
inuethemat e
rialstowardsothe
r
zone
so fbarrel
.The r
efore,thedesi
gne ffi
ciencyo fho p
p e
ralsoplayst hegre atrol
ein
pass
ingtheresinstome ltsmoot
hlyinthep rocess.

Bar
rel

Ine xtruder,thesur
faceoft hebarrelc
anbemac hinedo rsmooth.Smoothi
ngo rmachini
ng
theo ute
rs urfaceofextr
uderisdirectl
yrelat
e dtothehe atdis
p e
rsi
onratewhi l
eextruding.
Mo stextrudersareel
ectri
cal
lyheatedandu seresi
stancec o
il
s,bands,
orc uffsthatare
strappedo rbolt
edaroundthebarrel.Upondemand,init
iatedbyat hermocouple,
elec
trical
currentisp as
sedthrou
ght heresi
stancewire,
insi
det hecoil
.Theresi
stancep r
oducesheat
thatc ause
st hetemperat
uret ori
se

Sc
rew

Ani
mpo
rtanc
eoft
hes
cre
wine
xtr
udi
ngi
sthes
hap
eoft
hes
cre
w.Thes
cre
wus
edi
n
extr
u dersi
she li
cal
.Itsuniques hapep ro
duce smu c
hfr i
cti
onandhe atr equ i
redfo rmelti
ng
andp ushi
ngr awmat eri
alsforwar d.Ingeneral,alongscrewinsi
det hee xtrudercanbe
furtherdividedint
ofe eds e
ctio n,tr
ansiti
ons ect
ionandme teri
ngs ec t
ion.Thelengthofthe
scre
w( L/D)i sdescri
bedasar at i
ooflengthdi vi
dedbyt hescrewdi ame terthatismeasure
atflight.I
nfe edsectio
n, al
lther awmat erialsgetdownfr o
mfe e
dt hroatbygr avi
tyto
baseo frotati
ngs c
rewandge ti ncontactwithscrewandfu rtherpro cessofe xt
ruding
begins.

Di
e

Dieplaysanimport
antrolei
nde te
rmini
ngtheshapeoftheproduct.
Inthethermaldes
ign
,
thehe ati
ngofthelandsect
ionofthedi
eisspl
itinto8to12zonesarou
nditsperi
pher
y.
Thesez o
nesarethermal
lysepar
atedbyairgap
s .
Thet e
mp er
atureofeachzoneis
separatel
ycontr
oll
edintherangefrom180C̊to1 9
9C̊toadjus
tthep i
pethi
ckness
dis
t r
ibuti
on.

Wat
erCo
oli
ngTub

Whenho textrudercome souto fthedi e,i

tissupp o
sedt obeho tands oft.Forc oo
li
ng
proc
esse xtr
ude rpipefurtherp r
oc e
sst hroughlongchambe rt obathtu b.Thes p
ecifi
c
amounto fheati sl
ossinwate rwhichr esul
tsinthes ol
idi
ficationofpro fi
les.Theusedorhot
waterreturnwat erbacktot hec entralcool
ingunit.Andt hiscool
ingcyc l
ec o
nt i
nues
thro
ugho utthep ro
cessofc ooli
ngp i
pe sorplast
icp ro
files
. Waterinthet ubwasi nroom
temperaturerangingfr om22 °C-2 6°
C. Thesuppl
yo fwat ert othetubwasc onti
nuousflo
w
ofwater.

Cat
erpi
ll
arHaul
-Off

Fo
rp i
pesands omep r
ofi
les
,whe rethee xt
ru derisrigi
d, acate
rpil
larhaul-offisthemo s
t
sui
table.Thesi
mp l
esttypeconsist
soft woru bberbe l
tsthatrotat
e, oneabo v
et heothe
r,
andgr i
pt heext
ruderbetweenal ongparall
el se
ctionoft hetwobelts.Si
nc ethep u
ll
ing
forcescanbequ i
tehigh,
thele ngthofthec aterpil
lartrackshoul
dbes ufficientto
generatet hep
ull
ingforc
ewit houtmarkingt heextruder.

Par
amet
ers

Toext
rudep las
ticp
ipes,
itisveryimportanttoco
nsi
derallthenec
essaryparameters
,
temper
atu r
eandp res
surereadingsacco
r di
ngtomateri
alchoset
obep roce
ssed.Facto
rs
l
ikemelt
ingt emper
ature,dryi
ngt emperatur
e,pr
essur
e,speedofscr
e w,motor
,plac
eme nt
ofdi
egr eatl
yaffectsthep os
sibl
ee x
truderinex
tru
sion.

Pr
oces
s

Re
sinsar
epl
ast
icgr
anu
lesge
ner
all
yrange
dinv
ari
ouss
ize
s.The
rear
emanyt
ype
sofr
esi
n
avai
lable
. Sel
ectionofresi
nisdo neacco
rdingtoproductrequi
red.Co mmonr e
sinsuse dal
l
ov
e rplasti
cindustri
esarePE1 0 0,
PE1 00+Granu l
esthataremanu facturedat17 0
° C-
190°C.Differentresi
nfoll
owst hediffere
ntstandardofme l
tflowi ndex,
sinceallthe
mate r
ial
shav ediffere
ntme l
tingp oi
ntandcrystal
li
zati
ontempe r
atu re
.

I
nthecont
inuo
uspro
ces
sofpip
ee x
trudi
ng,fi
rstl
yt heres
inswer
ecarefu
ll
yche
ckedand
t
hendri
edinthemix
tur
echamber.
1.
2% moi
s t
uriz
inggranul
ewasmixe
dasanaddit
ivet
o
r
esi
n.Te
mp er
atur
eindrye
rwasrangedfro
m8 0
°Cu pto90°C.

Whol
eextr
udere
ffi
ci
enc
yde
pendsu
ponho
wwe
lle
xtr
ude
rishe
ate
dandfu
nct
ionss
moo
thl
y
wi
thres
ins.

Thee
xtr
ude
rwasp
re-he
ate
done
achc
hanne
l:

 Te
mpz
one1
=16
2°C

 Te
mpZo
ne2
=16
3°C

 Te
mpZo
ne3
=16
5°C

 Te
mpZo
ne4
=18
5°C

 Te
mpZo
ne5
=18
7°C

Thec ontrolboxi np utsupplyfr o

mami ni
mu m2 40Vge ne rat o
rs u itablet odr i
vei nduc ti
ve
loadsandp hasel oadsc uts ystems ,inc l
ude ds afe tyde vi
c es.Thegr anu leswer efe dma nually
intotheho p peraft erdr ying2 .5hr sindr yingc hambe r .
The nt her awmat erialswe re
imme diatelypas se dthrought het hroato fho p
pe rviagr avit
y. Whe nt hemat e ri
alsr eache d
atbas e,thes crewbe gant op usht hemat e rials.Thehe atge ner at edv iafrictionande xte rnal
he atpushesandme l
tsre s
insmi x t
u refo rwar d,towar dsTe mpz o ne1and2 .Thet emp eratu re
wask ept1 62°C-1 63°Cre spe c
t i
vely. Re s
inswass tartingt ome l
ts lowlyandmo vi
ngfu rther
toTe mpz one3 ,t het emp e
r atu r
eo ft hezo ne3was1 6 5°C. Whe nt her e si
np assedTe mpz one4
andr eachedTe mpz one5 ,themi x
t ureo fr awmat eri
al swasc omp let e
lyme l
te dandi nnice
ho mogenouss tate .TheTe mpi nz o
ne4and5was1 85°Cand1 87°C, respecti
v ely.Thee xt r
u der
wast henp assedt hroughac hambe rfo rc ooling.Ane xtru derne e dedt obedi me nsi
o nall
y
ac cur
atewi thoutanys agso rthick ene dre gions;t here forc ente rp i
eceo ft hedi ewass hift
do wnwards. Nowt hep i
pewe ntt hroughl ongwat ert ubfo rcooli
ng. Wat erint het ubwasi n
roo mtemp e r
at u
r er angingfr o m2 2°C-2 6°C. Thes u
pp lyo fwat e rt ot het ubwasc ontinuo us
flowo fwa ter.

Whenthepi
pereac
hedtheendofthebat
htu
bandfi
nis
hedc
ool
ingp
roc
ess
,thee
xtr
ude
r
pi
peswerecutt
osiz
eattheend.

Tabl
esho
wings
eri
eso
fex
tru
sio
nte
stt
emp
erat
urefo
rmak
ing5di
ffe
rentSt
andar
d
Di
mens
ionalRat
iop
ipe
s

Exper
ime Mat
eri
al T1(
°C) T2(
°C) T3(
°C) T4(
°C) T5(
°C) Out
er Minwall
nttri
als di
amet
er ti
ck-nes
s

1 HDPE 1
49 1
50 1
60 1
75 1
87 1
6 1
.6

2 HDPE 1
50 1
63 1
64 1
75 1
88 2
5 2
.3

3 HDPE 1
55 1
60 1
64 1
80 1
95 4
0 3
.7

4 HDPE 1
57 1
65 1
65 1
80 1
95 6
3 5
.9

5 HDPE 1
60 1
63 1
70 1
90 1
95 1
10 1
0.0

Pr
ess
ureo
fVac
uumTank3
00Ps
i-5
00Ps
i

Ge
ner
alTe
mpe
rat
ureu
sedi
nsi
det
hebar
rel
forHDPEp
ipemanu
fac
tur
ingi
s;

Zo
ne1=1
62°
C

Zo
ne2=1
62°
C

Zo
ne3=1
76°
C

Zo
ne4=1
82°
C

Zo
ne5=1
90°
C

Ac
tual
temp
erat
ures
tandar
disdi
ffe
rent
,de
pendi
ngo
ngr
adeo
fre
sinu
sed.

QUALI
TYCONTROLANDQUALI
TYASSURANCE

Assuringt hego o
dqu alityrawmat eri
alst obeu sedinthep ro
duc ti
onofp ipe sisthefi rs
t
essentialands i
gnificantc ondit
ionforc o
mp li
ancewitht hespec
ificneedso ft hefinished
produc t.HDPEr e s
insu sedt omakep olyethylenepipemu stbeanalyzed,tes tedand
approve dforu set oe nsurenecessi
ties.Thep i
pema ker'scommit mentincl
u de stesting,
randoml yp i
ckeds amp l
esfr o
me achp artlotfo rcert
ifyingdensity,meltinde x ,t
ens i
le
strengt hande nvironme ntalstre
ssc r
ac kr esi
stance.
Forr efere
nc eandgat her i
ngp roces
s
controlp urpo
ses,re cognizedmat er
ialp ackagesshoul
dbedo l
edo utrecognizingnu mbe rs.
Permane ntrecordss houldbek ept.Cont r
oloft heideaoft hepipedeli
v er
ingp rocessisthe
accomp anyingfu ndame ntalandessentialconditi
onforc onsi
stenceconsol
idat e sthego i
ng
with.
Cont
rol
li
ngthemanu
fac
turi
ngpr
oce
ssisthenextsi
gnifi
cantst
ep.
Ahi
ghl
yre
comme
nde
d
qu
ali
tycont
rolp
rogr
amformanu
factu
ringpro
cessisasfoll
ows
:

 Ser
iousexami
nati
onofev
erymo
veme
ntu
singv
isu
alandi
naddi
ti
onau
tomat
ed
i
nspec
t i
onpro
cedure
s.

 Te
sti
ngt
rialo
fthefi
nis
hedp
ipe
,do
neatp
rede
ter
mine
dfr
equ
enc
y.

Des
p iterec
ordsoft heabovethings,
andt oens
u r
etraceabi
li
tyofthemadep ipe,qual
ity
controlre
p o
rtsmu streco
rdt heplant
,dateandmo veofmanu fac
ture,
p ro
ducti
o nl
ineand
resi
n. Eachmodifyingthi
ngo ughttobeident
ifiedwit
he ndur
ingmarkingsex
hibiti
ngthe
manu factur
er,creati
ngp l
ant,dateofproducti
on,app
li
cablespec
ifi
ctaskandt hepipe
's
nominaldiameter.

StandardQuali
tyCont
rolpr
ogr
amwi l
lfusei
rre
gularau
dit
soft
hefe
asi
bil
it
yoft
he
pr
o gramit
self.Su
chsurv
eyswi
llge
neral
lyaddres
s:

 Ev
alu
ati
ono
fmanu
fac
tur
edp
ipeandfi
tti
ngsi
nst
ock

 Examinat
ionandr
ecal
ibr
ati
on(
iffu
ndame
ntal
)ofQu
ali
tyc
ont
rolt
est
ing
i
nstru
me nt

 Qu
ali
tyc
ont
rol
exami
nat
iona
ndr
epo
rti
ngs
yst
ems

 Rawmat
eri
alr
evi
ewi
ng,
tes
tingandp
ack
agec
ont
rols
yst
ems

 Pr
odu
ctac
cre
dit
ati
ont
echn
iqu
es

 Co
ll
ect
ingc
ust
ome
rfe
edbac
ks;he
lpfu
lex
erc
ise
s

 Pr
oce
ssi
ngo
fre
comme
ndat
ionsfr
omp
lantp
ers
onne
l

Pr
epar
edbyEs
ubal
ew.
A