DIE DEVELOPMENTS | MACHINERY
In the toolbox: die developments
Recent developments in dies include a software module to minimise pulsation, designs that combine PE with other materials and a product with short flushing times
Die design is critical to the final product quality of pipes and profiles – and can help to boost product quality while saving cost through factors such as tight control of dimensions. Battenfeld-Cincinnati says that its Helix II 32-5 VSI five-layer pipe die – which boasts easy handling and short flushing times – has been designed for sustainability. The company presented it at K2022 last year, in
combination with its new SolEx 45NG single screw extruder – in a way which allowed visitors to see the design of the flow channels and melt distribution system. Easy handling and minimal material losses were the main goals when developing the new product line. Pipe dies normally need to be taken apart and
cleaned from time to time. For smaller multi-layer dies in particular, this may often be necessary. Sometimes, processed materials are changed at short intervals, or tend to form deposits. In these cases, easy handling of the equipment is vital. This was taken into account in the development of the new pipe die, says the company. Firstly, the number of individual components has been reduced; and secondly, most components are centred via a cone, which ensures maximum user-friendliness and prevention of faults.
Another focus was in optimising the flow channels. The objective was to minimise flushing
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times, to make changeover more efficient. A simultaneous target was to ensure high precision in layer distribution across the entire circumference of the pipe. All of this could be achieved by combin- ing the melt distributors of several different designs. In this way, the average residence time – a good indicator of expected flushing time – was reduced by more than 50%. The die shown at K2022 was designed for PE pipes with external diameters ranging from 6 to 32 mm with an output of 350 kg/h. The entire pipe die series with spiral mandrel – a spiral distributor combined with a lattice basket – comes in 15 different sizes. It covers pipe dimensions ranging from 4 to 3,000mm and possible outputs from 300 to 3,000 kg/h.
Pulsation-free PVC At last year’s K show, the company also presented Steady flow – an extra module that can minimise pulsation in PVC extrusion. This helps to ensure continuous, even output – and raise the quality of semi-finished products. The patent pending new software module is already being used by several customers. When processing PVC on counter-rotating twin
screw extruders, pulsations of the material flow are unavoidable. These are caused by the C-shaped chamber profiles formed by the pair of screws.
� May/June 2023 | PIPE & PROFILE EXTRUSION 23
Main image: Battenfeld- Cincinnati’s Helix five-layer pipe die boasts easy handling and short
flushing times
IMAGE: BATTENFELD-CINCINNATI
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