What is HDPE Pipe Extrusion Line?
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The Complete Guide to HDPE Pipe Extrusion Line: Components, Process & Innovations An HDPE pipe extrusion line
Parameter
Specification
Applicable Material
PE
Production Pipe Diameter Range (OD)
0-Φ315 mm
Production Line Output
0-650 kg/h
Center Height
1200±50 mm
Operation Direction
Right to left (→)
Machine Color
Customizable per client requirements
Total Installed Power
360 kW
Voltage Requirement
380V/50Hz, Three-phase
Operating Environment
Indoor, non-hazardous electrical area
Humidity
≤85% (non-condensing)
Cooling Water Requirements
≤20℃, ≥0.3 MPa
Compressed Air Requirements
1 m³/min, ≥0.6 MPa
Core Components of an HDPE Pipe Extrusion Line
No.
Equipment Name
Qty
1
QX-900 Automatic Vacuum Loading System
1 Unit
2
QX-150 Hopper Dryer
1 Unit
3
QX-300 Automatic Vacuum Loading System
1 Unit
4
QX-50 Hopper Dryer
1 Unit
5
SJ75/38 High-Speed Single Screw Extruder
1 Unit
6
SJ50/33 Single Screw Extruder
1 Unit
7
Gravimetric Control System (Dual-layer)
1 Set
8
SJ25/25 Co-extruder for Color Stripe
1 Unit
9
Φ315mm Three-layer High-speed PE Pipe Die
1 Set
10
315 Pipe Vacuum Calibration Tank (9m)
1 Unit
11
315 Pipe Spray Cooling Tank (8m)
2 Units
12
315 Four-claw Crawler-type Servo-driven Haul-off Machine
1 Unit
13
315 Pipe Orbital Chip-free Cutting Machine
1 Unit
14
Pipe Turning Rack
1 Unit
1、Extruder
SJ75/38 High-Speed Single Screw Extruder
Parameter
Specification
Extrusion Output
300-600 kg/h
Operation Mode
Knob Control Panel
Motor Power
160 kW, AC
Center Height
1200±50 mm
Screw
∟ Screw Diameter
75 mm
∟ L/D Ratio
38:1
∟ Screw Speed
0-180 rpm
∟ Speed Control
Variable Frequency (ABB Inverter)
∟ Screw Material
38CrMoAlA, Nitrided Treatment
∟ Nitrided Layer Depth
0.5-0.8 mm
SJ50/33 Single Screw Extruder
Parameter
Specification
Technical Notes
Extrusion Output
30-80 kg/h
Covers laboratory to pilot-scale production
Operation Mode
Knob Control Panel
Manual precision adjustment
Motor Power
37 kW Permanent Magnet Servo Motor
High torque efficiency (±0.1% speed stability)
Center Height
1200±50 mm
Standard pipe line integration height
Screw
∟ Screw Diameter
50 mm
Balanced shear rate for HDPE/PP
∟ L/D Ratio
33:1
Optimized for HDPE pipe stability
∟ Screw Speed
0-110 rpm
Wide range for material adaptability
∟ Speed Control
Variable Frequency (Yaskawa Inverter)
Precision drive with overload protection
∟ Screw Material
38CrMoAlA, Nitrided Treatment
Industry-standard alloy steel
∟ Nitrided Layer Depth
0.5-0.8 mm
Enhanced wear resistance (HV≥800)
SJ25/25 Co-extruder for Color Stripe
Parameter
Specification
Technical Notes
Extrusion Output
1-5 kg/h
Lab-scale precision
Operation Mode
Rotary Knob Control Panel
Manual fine-tuning
Motor Power
1.5 kW, AC
Standard industrial drive
Center Height
1000±50 mm
Low-profile design
Overall Dimensions
1400×720×1400 mm (L×W×H)
Compact footprint
Screw
∟ Screw Diameter
25 mm
Micro-extrusion
∟ L/D Ratio
25:1
Optimal for low-volume melts
∟ Screw Speed
0-20 rpm
Ultra-slow processing
∟ Speed Control
Variable Frequency Drive (VFD)
Smooth startup
∟ Screw Material
38CrMoAlA, Nitrided Treatment
Wear-resistant alloy
∟ Nitrided Layer Depth
0.5-0.8 mm
Extended service life
2、Gravimetric Control System (Dual-layer)
Component
Specification
Technical Notes
Touch Screen
7-inch Touch Screen HMI
Color graphical interface
PLC Control
PLC Control System
Centralized automation
Gravimetric Hopper
Stainless Steel (SS304/SS316) with Support Frame × 2 units
For precise material dosing
3、Mold
Parameter
Specification
Technical Notes
Heating Method
Mica Band Heater
Uniform temperature distribution (±2°C)
Die Material
40Cr Alloy Steel
Quenched & tempered (HRC 28-32)
Mandrel Material
40Cr Alloy Steel
Mirror polished (Ra≤0.2μm)
Sizing Sleeve Material
High-Wear Bronze Alloy
Brinell hardness ≥HB 110
Sizing Sleeve Cooling
Water-Cooled Jacket (Aluminum)
Rapid heat dissipation
4、Shaping and Cooling
Parameter
Specification
Technical Notes
Vacuum System
∟ Vacuum Pump Power
5.5 kW × 2
Dual-pump redundancy design
∟ Water Pump Power
5.5 kW × 2
High-flow circulation (≥15m³/h)
Cooling System
∟ Cooling Method
Spray Cooling
Uniform pipe surface quenching
∟ Spray Bars
8 units
Full-coverage layout
∟ Spray Bar Material
Thickened Stainless Steel (SS304)
Corrosion-resistant construction
∟ Nozzle Material
Nylon (PA66)
Clog-resistant, 200k+ cycle life
Positioning System
∟ Adjustment Motor Power
1.5 kW
Servo-controlled precision
∟ Vertical Adjustment Range
±50 mm
Pipe centering accuracy ≤0.5mm
∟ Horizontal Adjustment Range
±30 mm
∟ Longitudinal Adjustment Range
800 mm
Die-to-tank alignment compensation
Tank Construction
∟ Vacuum Tank Length
9,000 mm
For Ø315mm pipe at 1.5m/min line speed
∟ Tank Wall Thickness
5 mm Stainless Steel
Structural rigidity (deflection <1mm/m)
∟ Center Height
1000±50 mm
Matches extruder output height
∟ Wetted Surface Material
Stainless Steel (Full 9m contact zone)
ISO 2143 compliant for water corrosion
Parameter
Specification
Technical Notes
Water Pump Power
7.5 kW × 1
High-pressure circulation (≥20m³/h)
Cooling Method
Spray Cooling (Curtain-Type) with Glass Viewport
Uniform full-coverage quenching
Spray Bars
8 units
360° nozzle arrangement
Spray Bar Material
Thickened Stainless Steel (SS304)
Anti-corrosion design
Nozzle Material
Nylon (PA66)
Clog-resistant, self-cleaning jets
Spray Tank Length
8,000 mm
Optimized for Φ315mm pipe cooling
Tank Wall Thickness
2.5 mm Stainless Steel
Weight-optimized structure
Center Height
1200±50 mm
Matches upstream/downstream equipment
Wetted Surface Material
Stainless Steel (Full 8m contact zone)
ISO 2143 corrosion compliant
5、Hauling off
Parameter
Specification
Technical Notes
Traction System
∟ Crawler Units
4 sets
Independent force balancing
∟ Frame Length
2,800 mm
Optimized for Φ315mm pipe stability
∟ Max Traction Force
18,000 N (≈1,836 kgf)
Sufficient for 630mm SDR11 pipes
∟ Traction Speed Range
0.1-8 m/min
Precision control for thin/thick walls
∟ Drive Motors
1.5 kW Servo Motors × 4
Sinusoidal servo system (±0.05% sync)
∟ Speed Control
Servo Controller Regulation
CANopen bus synchronization
∟ Clamping Method
Pneumatic Clamping
Fail-safe grip pressure
∟ Air Pressure
0.6 MPa
Instant response <0.5s
∟ Center Height
1200±50 mm
Matched to upstream cooling tanks
Electrical Components
∟ Motors & Gearboxes
Sinusoidal Servo Motors + K-Series Gearboxes
IP54 protection, 20,000h service life
∟ Speed Controllers
Sinusoidal Servo Drives
Torque ripple <0.2%
∟ Contactors/Indicators/Buttons
Schneider/DELIXI components
IEC 60947-4 compliant
6、Cutting
Parameter
Specification
Technical Notes
Max Cutting Thickness
30 mm (HDPE)
For SDR17 Φ315mm pipes
Feed Mechanism
Hydraulic Feed
Pressure-controlled (±0.2mm precision)
Cutting Blade
Customized Tool Steel Blades
Hardness ≥62 HRC, replaceable inserts
Motor Power
2.2 kW
Constant-torque design
Rotational Speed
960 rpm
Optimized for clean chip-free cuts
Stroke Control
Pneumatic Cylinder Actuated
Repeatability ±0.1mm
Table Travel
1,500 mm
Handles 6m pipe segments
Table Drive
Pneumatic Slide System
0.6 MPa air pressure, rapid positioning
Center Height
1200±50 mm
Matched to upstream haul-off unit
7、Racking
Parameter
Specification
Technical Notes
Rack Type
Pneumatic Turning Rack
Automated pipe rotation after cutting
Rack Length
6 m
Handles standard 6m pipe segments
Control Method
Automatic
PLC-synchronized with cutting cycle
Compressed Air Pressure
≥0.6 MPa
Consistent with plant air system
Dimensions (L×W×H)
6000×800×1200 mm
Optimized footprint for production line
How the Extrusion Process Works: Step by Step
1. Feeding: HDPE pellets enter the hopper, often with drying units to remove moisture.
2. Plastification: Pellets melt in the barrel (130–180°C) under controlled shear.
3. Extrusion & Shaping: Melt is forced through a die to form a pipe profile.
4. Cooling: Pipes pass through water baths for solidification (prevents deformation).
5. Pulling & Cutting: Precision haul-offs and saws cut pipes to specified lengths.
Key Applications Driving Demand
Municipal Water/Gas Networks: Pressure-rated pipes (20–630 mm) with leak-free joints.
Sewage & Drainage: Large-diameter (up to 3,000 mm) structured-wall pipes (e.g., steel-reinforced HDPE) for corrosion resistance.
Mining & Irrigation: Mobile extrusion units enable on-site pipe production, reducing transport costs.
Technological Innovations & Trends
High-Output Designs: Dual extruders boost output (e.g., 950 kg/h for Ø630 mm pipes).
Smart Manufacturing: IoT-enabled controls for real-time quality tracking and predictive maintenance.
Modular Systems: Mobile plants (e.g., Tubi’s patented units) produce long, weld-free pipes onsite, slashing logistics costs.
Energy Efficiency: Barrier screws and optimized L/D ratios reduce power use by 15–20%.
Table: Output Comparison by Extruder Type
Screw Diameter (mm)
L/D Ratio
Max Output (kg/h)
Pipe Diameter Range
65
33:1
800
20–110 mm
90
36:1
950
200–630 mm
150
30:1
1,700
Up to 1,200 mm
Emission Control: Non-methane hydrocarbons from heating are treated via plasma/activated carbon systems.
Waste Reduction: Scrap plastic (off-cuts/defective pipes) is recycled into pellets for reuse.
Lightweighting: HDPE pipes weigh 1/8th of steel alternatives, lowering transport emissions.
