What is HDPE Pipe Extrusion Line? Views: 0 Author: Maggie Publish Time: 2025-08-01 Origin: Site
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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.
