Extrusion Die Heads › ... › 05 › TESTE-ENG-2019.pdf · “Technological innovation is at the...

Extrusion Die Heads

APPLICATIONSDesigned to fit the customers needs and their pipe production the Tecnomatic’s extrusion machines are the ideal solution to manufacture pipes with a range from 5 to 2600 mm. They are employed for the extrusion of many materials and for different applications: PE 63, PE 80, PE 100 smooth water & Gas pipes, Irrigation, telecommunication, PE or PP Corrugated non-pressure sewage and cable protection, reinforced pipes or steel-coated and plastic pipes.

HDPELarge bore pipes up to 2600 mm

Water & gas high-pressure pipes

Pipes for conduits and mining

Corrugated pipes for cable conduits,

drainage and sewage

Telecommunication and micro-duct pipes

Multi-layers or steel pipes coating

LDPE, LLDPEIrrigation and agriculture pipes

PPHot & cold water sanitary pipes

Corrugated drainage and sewage pipes

Large diameters pipes for chemical industries

PE-XMono or multi layers pipes with

oxygen barrier (EVOH) and aluminium

for hot water application

PVCPressure and non-pressure application

Gardening, wire reinforced,

food & beverage, marine hoses

ABS, PC, PA, PPSTechnical polymers pipes and hoses

“Technological innovation is at

the heart of our projects”

Die-Heads

A state of the art design for plastic pipe manufacturing

Renowned as a leading pipe head manufacturer for

Polyolefin and PVC pipes, Tecnomatic offers a brand

new pipe heads generation characterized by three

different design solutions. VENUS, based on a helical spiral design for monolayer and multilayer pipes

from 5 mm up to 2.600 mm. ATHENA, a cutting-edge

technology made of radial spiral modules for multi-

layer pipes (up to 7 layers) for hot water application

and specific product requirements. JUNO, the hybrid

system (helical + radial) for the extrusion of medium

and large multilayer (up to 5 layers) district heating

pipes, with oxygen barrier requirement. Along with

the production of PO pipe heads Tecnomatic offers

the series HERA to accomplish the requirement of

the PVC pipe manufacturer. Part of the history and

core business for many years, the HERA PVC die-he-

ads, are designed up to a size of 1.200 mm diameter,

and successfully sold all over world.

Segmented mandrel

Easy remove operation

for thickness change

Mandrel 1

PAC

Pipe Air Cooling

3

Female die

4

Centering

Screws

5

2

“Constant research and forward thinking development to ensure relevant innovative extrusion solutions combined with excellent customer service,

passion and knowledge of the pipe industry.”

4

Melt distributors

Short in length to low volume and

pressure

8

Venus Coex-Unit

Radial spiral tecnology

for external layer

6

New spiral geometry

to increase output and equal wall thick-

ness dstribution, for mono or multilayer

pipes

7

PAC

Pipe Air Cooling9

About

6

Venus 1200

PIPEHEAD

Dimension range

Throughput PE Kg/h

Throughput PP Kg/h

Segmented mandrel

Pipe Air Cooling (PAC)

Spiral heating

Mandrel heating

Heating & cooling (HCS)

Mandrel cooling (HCS)

VENUS 160

16-160

500

400

From Ø 75 mm

No

Yes

For PE-RT & PP

No

No

VENUS 400

16-400

800

600

From Ø 75 mm

From Ø 140 mm

Yes

From Ø 140 mm

No

No

VENUS 630

50-630

1.200

1.000

From Ø 75 mm

From Ø 140 mm

Yes

Yes

From Ø 140 mm

From Ø 250 mm

VENUS 1200

355-1200

1.500

1.200

Yes

Yes

Yes

Yes

Yes

Yes

VENUS 2600

1.400-2.600

3.000

2.000

Yes

Yes

Yes

Yes

Yes

Yes

VENUS 1600

500-1600

2.000

1.400

Yes

Yes

Yes

Yes

Yes

Yes

venusVenus Monolayer

Lower investment in terms of €/Kg throughput of the pipe head.Smooth flowing to keep the material properties unchanged.Short die-set and segmented mandrels allow an easy and quick die-sets change, reducing the line downtime. Even wall thickness distribution for lower overweight of pipe and raw material saving.Pipe Air Cooling (PAC) system to short the cooling and to improve the pipe quality.

Your benefits at a glance

Expression of skill and experience as die-head designerThe VENUS design is based on a long time experience in developing, producing and selling die-heads for polyolefin materials. Conceived for conventional and standard pipes, the Venus concept is also available for the production of micro ducts, in range 3 to 16 mm, and up to 800 mm in a cross version, for the coating of steel, plastic, composite, corrugated and umbilical pipes.

The VENUS single layer pipe heads have

implemented important technological features in

order to reach the best pipes processing and to fit

a wide range of materials at very high output. The

spiral geometry has been especially optimized for

latest generation of PE and PP raw materials, while

length, volume and pressure have been reduced.

VENUS 1600 & 2600 set a new technology

standard for the production of large diameter pipes.

The main innovation is that two extruders are used

thanks to the new distribution split into two spirals,

each one fed by one extruder. The spirals have the

same geometry and are short in length to cut the

residence time. Based on a swelling production

mode (for a better control of wall thickness

distribution and pipe ovality) the die-heads grant

higher outputs, low working pressure, optimal melt

distribution and easier and quick die-sets change.

Main technical features:

• New melt feeding system and spiral geometry to

reduce length, volume & pressure.

• Same flow behavior in all die-heads.

• All pipe heads endue internal Pipe Air Cooling

(PAC).

• New die design 50% shorter and reduced

residence time.

• Die sets fit on different pipe heads models.

• Wider production range per die set.

• Bigger heads with internal Heating Cooling

Systems (HCS), by water.

• Compact design reduces heating power &

assembling time.

• Co-extrusion ring for thin outer layer, with radial

system.

Venus Coat 800

Venus 630 spiral distributor

Venus Microduct 200

According to requirements, custom fitted solution are engineered and offered to maximize performance, cost saving, and space, without compromising product quality.

PIPEHEAD

Dimension range

Throughput PE Kg/h

Throughput PP Kg/h

Segmented mandrel

Pipe Air Cooling (PAC)

Spiral heating

Mandrel heating

Spiral cooling (HCS)

Mandrel cooling (HCS)

VENUS

MULTI 125

16-125

500

400

For Ø 75mm

No

Yes

For PE-RT y PP

No

No

VENUS

MULTI 160

16-160

800

600

From Ø 75mm

From Ø 140mm

From

From Ø 140mm

No

No

VENUS

MULTI 250

50-250

1200

1000

From Ø 75mm

From Ø 140mm

Yes

From Ø 140mm

No

No

VENUS

MULTI 500

75-500

1500

1200

Yes

From Ø 140mm

Yes

From Ø 140mm

No

No

VENUS

MULTI 1200

250-1200

2000

1500

Yes

Yes

Yes

Yes

Yes

Yes

VENUS

MULTI 630

90-630

1700

1300

Yes

From Ø 140mm

Yes

From Ø 140mm

Yes

Yes

Venus Multi 3 800-R

8

The key component in any multilayer pipe

production line is the die head. Tecnomatic with

Venus Multi has developed a system based on

multiple spirals design to ensure the optimal

melt flow for a wide range of thickness ratios.

The die-heads are extremely compact with a low

pressure build-up and consequent energy savings.

Lower pressure also results in a lower increase of

the melt temperature assuring improved pipe’s

characteristics with regard to OIT (Oxidative

Induction Time) values, extra weight and thermal

and shear stresses reduction. The die-sets comprise

of two parts with a small end ring to define the

gap of the die, permitting a rapid size change

and adjustment. A Pipe Air Cooling (PAC) system

provides intensive cooling of the inner pipe surface

by sucking air in the opposite direction to extrusion.

Main technical features:

• The spirals’ geometry of Venus Multi ensures an

optimal layers distribution and even thickness.

• Venus Multi die sets are interchangeable with the

Venus monolayer ones.

• Wider production range per die set.

• Compact design reduces heating power &

assembling time.

• Venus Multi pipe heads are compatible with the

Pipe Air Cooling (PAC) system.

• The design allows the production of multilayer

large diameter pipes up to 2.600 mm.

• Bigger heads with internal Heating Cooling

Systems (HCS), by water.

Global market for complex plastic pipes with functional layers followed a technological evolution trend, with the emerging of functionality and cost saving requirements. Set up on Venus concept, Venus Multi is the appropriate die-head system for the production of two, three or four layers polyolefin pipes.

venusThe flows melting point is designed to adapt to a wide range of thickness-ratios.Smooth flowing to keep the material properties unchanged.Short die-set and segmented mandrels allow an easy and quick die-sets change, reducing the line downtime. Even wall thickness distribution for lower overweight of pipe and raw material saving.Pipe Air Cooling (PAC) system to short the cooling and to improve the pipe quality


Venus Multilayer

Supreme technology for multilayer solutions

Venus Multi 3 160

Venus Multi 4 250

Venus Multi 2 250

10

The system provides intensive cooling of the inner

pipe surface by sucking air in the opposite direction

to extrusion. By forcing the airflow, it ensures

uniform cooling around the pipe and through the

wall thickness, decreasing the differences in the

pipe solidification rate and reducing the residual

internal stresses. This also has the benefit of

reducing the wall thickness eccentricity and ovality

whilst providing the opportunity to have a short line

or to obtain higher output compared to a standard

line without inner cooling.

The effect of Pipe Air Cooling on “Slow Crack

Growth Resistance”. Simultaneously cooling of both

the outer and inner walls:

• Decrease the difference in the solidification rate

across the pipe.

• Reduce the residual internal stresses in PE pipes.

• Decrease the PE crystal thickness and increase

the number of tie molecules in the inner wall

(which is a key parameter determining the

resistance to SCG).

• Compared to the PE pipe produced by the

conventional extrusion, the crack initiation time is

increased and crack growth rate is slower.

An efficient system to reduce cooling length and to improve pipe quality. Extrusion lines for pipes got longer due to higher extruders output. The PAC system helps to reduce the length of the production lines thanks to its high efficiency in the internal pipe cooling. The Pipe Air Cooling allows a uniform cooling, 360° round and across its thick wall, improving the pipe quality itself.

Pipe AirCooling (Pac)


Shorter length or higher output speed of the extrusion line. Reduced volume of water or cooling capacity compared to conventional line configuration.Less thermal load to the inside surface (less thermal oxidation of inside surface, therefore longer lifetime without brittle failure). Reclaimed energy use from heat-ed air is possible for material pre-heating purposes.Uniform cooling is reducing stress distribution.

PAC System ducts

Options

venus

Options

venusExternal layer coex-unit


Radial spiral has low pressure built up and high throughput.Optimal layers distribution and even thick-ness (thin or thick), part of the total SDR wall.Venus pipe-heads can be upgradedanytime to multilayer solution, with the adoption of an external layer coex-unit.

In the same way of an axial spiral mandrel

distributor of cylindrical design, the flat radial

distributors are characterized by a uniform volume

flow and hence an excellent layer thickness

distribution, as well the absence of weld lines

and other weak points. The radial distributor is

a flat helical spiral, the melt flows to the tooling

centre through feeding channels and then

circumferentially distributed. When functional

external layers are required, the radial coex-unit

offers the ideal solution. The coex-unit is available

in several units and can be applied on all the Venus

die-heads. Special units are used on multi-layers

solution to short the colour changes time.

A radial spiral technology for external layer application.The Venus coex-unit is a radial distribution ring system to produce a coextruded external layer out of PE, PE 100 RC, PP, PP foamed or any other special material. The outer layer thickness depends on the output ratio between the co-extruder and the main extruder, up to a max of 50% of total wall thickness.

Venus 160 with co-ex unit

12

Developed on radial distributors design, Athena is the most innovative solution in the production of pipes and allows a wide range of uses. Inspired by the blow film dies, it is made of modular discs for the production of small/medium pipes up to seven layers. Athena is an ideal solution for multilayer pipes for hot water application and specific product requirements mainly made of PE-X, PE-RT, PP-R, PP-RCT, PB and any bonding agent.

Athena Coat

Based on spiral or radial distributors are designed for

the coating of steel and plastic pipes, composite (e.g.

with aluminium), corrugated (third layer), telecom-

munication or umbilical pipes. Die-heads are manu-

factured in monolayer or multilayer models, covering

a working diameter range from 8 to 800 mm.


Short flow paths and low melt volume for a short residence time.Rapid material and colour changes.Optimal melt flow and layers uniformity.High flexibility in terms of layers structure (thick or thin layers and materials) and number of layers.Easy cleaning and a rapid assembling/dis-assembling operation.Lower costs compared to axial spiral structures.

Athenamultilayer line

athenaResearch & innovation meet functionality

Athena Multi Coat

Juno is a compact die-head that Tecnomatic has developed for special multilayer pipes; up to five layers. It is a hybrid system of radial distributors with classical helical spiral ones, for the manufacturing of district heating pipes (up to 1.000 mm), with tie layers and EVOH barrier to prevent the diffusion of gas between the foam cells and the environment and to avoid the permeation of oxygen and nitrogen (air) from outside to inside.


Short flow paths for anti-oxidation and bonding materials.Optimal melt flow and layers uniformity.Excellent thickness control in terms ofmicrons, for barriers and bonding materials.

Customer’s tailor-made die-head projects

Based on a long time experience in developing,

producing and selling pipe-heads for Polyolefin

Tecnomatic has also been working on solutions which

are able to fulfil the customer’s needs, and its special

requirements, with continuous innovation.

Some of the projects:

• Die-heads for special raw materials.

• Radial spiral crossheads, mono and multilayers, up

to four layers, for gas, oil, water, district heating

pipes to improve mechanical and environmental

stress cracking performance, insulation, corrosion

and thermal or UV stability.

• Spiralled grooved design with rotating mandrel for

telecommunication or geothermic pipes.

• Multiple pipes die-heads for telecommunication.

• Hybrid systems helical/radial spirals for multiple

special layers.

Junodie-head

Telecommunication2 layers die-head,with rotating mandrel

Special series for special pipes

PROD

UCTI

ON P

IPE

DIAG

RAM

FOR

RIG

ID P

VC

The HERA die-heads are designed for high extrusion output and to cover a production range from 10 to 1200 mm. The optimized profile of the pipe heads channels assures an even melt flow, low stress material load and excellent wall thickness distribution. Made from stainless or carbon steel, from European selected suppliers, they are chrome plated (40 μ) to preserve the surface from corrosion and wearing. Mechanical and thermal centring, with a segmented mandrel, allows an easy control over thickness distribution of the pipe. Mica or ceramic resistances and two different version of pipe head trolley (with manual or automatized regulation) complete the configuration of Tecnomatic’s Pvc pipe heads.


Designed for high extrusion throughput.Diameter range up to 1200 mm.Optimized channels profile for even melt flow.Low stress load of the material.Excellent wall thickness distribution.Quick thickness change thanks to segmented male system.Mechanical and thermal centering (from size 110 mm - Hera 25).Robust die-heads support trolleys.

Hera 100 V

14

heraTraditional, essential and performing

250 - 150 Kg/h

500 - 350 Kg/h

600 - 450 Kg/h 800 - 650 Kg/h

1000 - 800 Kg/h

1400 - 1100 Kg/h

TA100-VACT0 TA120-VACT0








DIA

GR

AM

MA

DI

PR

OD

UZ

ION

E P

ER

PV

C R

IGID

O (

U-P

VC

) - P

RO

DU

CT

ION

PIP

E D

IAG

RA

M F

OR

RIG

ID P

VC

- D

IAG

RA

MM

E P

OU

R L

A P

RO

DU

CT

ION

DE

TU

YA

U E

N P

VC

RIG

IDE

Ø T

UBO

PIPE

TU

YAU

mm

Norm

ativa

di r

iferim

ento

/ in

acc

ordi

ng t

o / S

elon

DIN

806

2

Norm

ativa

di r

iferim

ento

/ in

acc

ordi

ng t

o / S

elon

UNI

EN

1452

-2

Rif /

to U

NI E

N 14

01-1

M

ODE

LLO

TES

TA

PIPE

DIE

-HEA

D TE

TE P

OUR

TUY

AU

PRO

DUZI

ONE

PR

ODU

CTIO

N Kg

/h

S 1

S 2

S 3

S 4

S 5

S 6

S 20

S

16.7

S

16

S 12

.5

S 10

S

8 S

6.3

S 5

SN 2

SN

4

SN 8

SD

R 12

6 SD

R 51

SD

R 34

.4

SDR

21

SDR

13.5

SD

R 9

SDR

41

SDR

34.4

SD

R 33

SD

R 26

SD

R 21

SD

R 17

SD

R 13

.6

SDR

11

SDR

51

SDR

41

SDR

34

PN 2

.5

PN 4

PN

6

PN 1

0 PN

16

PN 2

0 PN

6

PN 6

PN

8

PN 1

0 PN

12.

5 PN

16

PN 2

0 PN

25

10

1.

0 1.

2

12

1.0

1.4

1.

5

16

1.2

1.8

1.

5

20

1.5

2.3

1.5

1.9

25

1.5

1.9

2.8

1.

5 1.

9 2.

3

32

1.

8 2.

4 3.

6

1.5

1.6

1.9

2.4

2.9

40

1.

8 1.

9 3.

0 4.

5

1.

5 1.

6 1.

9 2.

4 3.

0 3.

7

50

1.8

2.4

3.7

5.6

1.

5 1.

6 2.

0 2.

4 3.

0 3.

7 4.

6

63

1.9

3.0

4.7

7.0

1.

9 2.

0 2.

5 3.

0 3.

8 4.

7 5.

8

75

1.

8 2.

2 3.

6 5.

6 8.

4

2.2

2.3

2.9

3.6

4.5

5.6

6.8

90

1.8

2.7

4.3

6.7

10.0

2.7

2.8

3.5

4.3

5.4

6.7

8.2

11

0 1.

8 2.

2 3.

2 5.

3 8.

2 12

.3

2.7

3.2

3.4

4.2

5.3

6.6

8.1

10.0

3.2

3.7

125

1.8

2.5

3.7

6.0

9.3

13.9

3.

1 3.

7 3.

9 4.

8 6.

0 7.

4 9.

2 11

.4

3.

2 3.

2 14

0 1.

8 2.

8 4.

1 6.

7 10

.4

15.6

3.

5 4.

1 4.

3 5.

4 6.

7 8.

3 10

.3

12.7

160

1.8

3.2

4.7

7.7

11.9

17

.8

4.0

4.7

4.9

6.2

7.7

9.5

11.8

14

.6

3.2

4.0

4.7

180

1.8

3.6

5.3

8.6

13.4

20

.0

4.4

5.3

5.5

6.9

8.6

10.7

13

.3

16.4

200

1.8

4.0

5.9

9.6

14.9

22

.3

4.9

5.9

6.2

7.7

9.6

11.9

14

.7

18.2

3.

9 4.

9 5.

9 22

5 1.

8 4.

5 6.

6 10

.8

16.7

25

.0

5.5

6.6

6.9

8.6

10.8

13

.4

16.6

25

0 2.

0 4.

9 7.

3 11

.9

18.6

27

.8

6.2

7.3

7.7

9.6

11.9

14

.8

18.4

4.9

6.2

7.3

280

2.3

5.5

8.2

13.4

20

.8

6.

9 8.

2 8.

6 10

.7

13.4

16

.6

20.6

31

5 2.

5 6.

2 9.

2 15

.0

23.4

7.7

9.2

9.7

12.1

15

.0

18.7

23

.2

6.

2 7.

7 9.

2 35

5 2.

9 7.

0 10

.4

16.9

26

.3

8.

7 10

.4

10.9

13

.6

16.9

21

.1

26.1

7.0

8.7

10.4

40

0 3.

2 7.

9 11

.7

19.1

29

.7

9.

8 11

.7

12.3

15

.3

19.1

23

.7

29.4

7.9

9.8

11.7

45

0 3.

6 8.

9 13

.2

21.5

11

.0

13.2

13

.8

17.2

21

.5

26.7

33

.1

8.

8 11

.0

13.2

50

0 4.

0 9.

8 14

.6

23.9

12

.3

14.6

15

.3

19.1

23

.9

29.7

36

.8

9.

8 12

.3

14.6

56

0 4.

5 11

.0

16.4

26

.7

13.7

16

.4

17.2

21

.4

26.7

63

0 5.

0 12

.4

18.4

30

.0

15.4

18

.4

19.3

24

.1

30.0

12.3

15

.4

18.4

71

0 5.

7 14

.0

20.7

17.4

20

.7

21.8

27

.2

13.9

17

.4

80

0 6.

4 15

.7

23.3

19.6

23

.3

24.5

30

.6

15.7

19

.6

90

0 7.

2 17

.7

26.3

22.0

26

.3

27.6

17.6

22

.0

10

00

8.0

19.7

29

.2

24

.5

29.2

30

.6

19

.6

24.5

1200

9.

6 23

.6

14

00

11.2

27

.5

16

00

12.7

31

.4

Tab

ella

pro

duzi

one

tubi

in P

VC

-

rev

2.0

09.

2016

PROD

UCTI

ON P

IPE

DIAG

RAM

FOR

RIG

ID P

VC

agenziap.it

EXTRUSIONDIE-HEADS

Via Emilia, 4 24052 Azzano S.Paolo (Bergamo) Italytel. +39 035 310375fax +39 035 [email protected]

Extrusion Die Heads › ... › 05 › TESTE-ENG-2019.pdf · “Technological innovation is at the...

Documents

Transcript of Extrusion Die Heads › ... › 05 › TESTE-ENG-2019.pdf · “Technological innovation is at the...