PROCESSING | LARGE DIAMETER PIPE


Energy reduction Battenfeld-Cincinnati says it can help customers reduce energy consumption in the production of large-diameter polyolefin pipe. “Thanks to the process engineering design of the new SolEx NG single-screw series, we have reduced energy consumption by around 15% compared to previous generations,” said Andreas Türk, director of sales for infrastructure at Battenfeld-Cincinnati. This is critical, because the extruder can consume up to 80% of the energy needed for extrusion, he says. The main reason for this improvement is the internally grooved barrel, which has a low axial pressure profile combined with the matching screw geometry. This helps to reduce both energy consumption and machine wear. In addition, the new processing unit ensures a gentle, homogene- ous melting performance at around 10°C lower temperatures, he adds. The company’s helix dies – which combine a


screen basket distributor and spiral mandrel – use 10% less energy during heating compared to conventional pipe heads, he says. Developments in the pipe head also help to prevent sagging – a com- mon problem when making large-diameter pipe. The screen basket homogenises the melt thermally and mechanically, leading to further improvement in product quality. In addition, the cooling line works with frequency-controlled pumps and an efficient water supply, to further cut energy costs. A line comprising a SolEx NG, helix die and


‘green’ downstream equipment could save around €85,000 per year in energy costs – based on 7,000 hours/year of production and an energy price of €0.12 per kWh – when producing 250mm PO pipe with SDR 11 and an output of 1,000 kg/h. With a conventional energy mix, this is a CO2 equivalent of 315,000kg. Improved melt quality also helps to reduce the


tolerance ranges of the wall thicknesses in the pipe – helping to save material when combined with a gravimetric dosing system, an extruder that works with minimal fluctuation, and inline wall thickness control. The company cites an example: if the


target wall thickness of 6.2mm of a 200mm PO pipe with SDR 33 varies within a narrow tolerance range (6.22-6.48mm, rather than a more typical 7mm) , around €1m/year could be saved in raw material costs – for a throughput rate of 1,000 kg/h, 7,000 hours of annual production and an HDPE price of €1.50/kg. “The investment costs for complete pipe extrusion lines quickly pay off,” he said.


US expansion Canadian pipe manufacturer Soleno has opened its first US-based plant, at a site in Saratoga County in New York state. The new plant, which cost more than US$22


million, will initially focus on the company’s Kustomflo line of pipes – made using technology from Krah of Germany. The HDPE pipes “offer some of the largest diameters on the market and are known for their exceptional durability”, said the company. The pipes are used for water manage- ment infrastructure applications. Soleno says the new 45,000 sq ft facility will


operate seven days a week and also serve as a distribution centre. In future, a further 25,000 sq ft could be added if needed, as it sits on a 22-acre site. The plant’s first orders have already been shipped to Maine, Vermont and Massachusetts. The company expects to export around 20% of the plant’s output.


“Establishing a factory here allows us to reach a new level of efficiency and proximity to our markets,” said Mathieu Cornellier, general manager of the Saratoga plant. “Producing locally meets the specific needs of our US customers, and integrates sustainable solutions that will benefit our Canadian customers.” Soleno, based in Quebec, makes HDPE pipe at 10 facilities across Canada – and employs around 500 people.


Engineering centre US pipe manufacturer Advanced Drainage Systems (ADS) says that its new US$65 million engineering and technology centre in Hilliard, Ohio – a 110,000 sq ft research and testing facility


Battenfeld-Cincinnati says it can help cut energy costs when making large-diameter polyolefin pipe


16 PIPE & PROFILE EXTRUSION | Winter 2024


IMAGE: BATTENFELD-CINCINNATI


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