Application of co-extrusion technology in 7-25mm HDPE pipe production line

We understand that product performance is the most important in the competitive environment of high-density polyethylene (HDPE) pipes especially owing to critical small-diameter applications in pipe production in gas distribution, potable water supply and transfer of fluids to industries. It is observed that with pipes between 7mm and 25mm, industry needs longevity, safety and cost-efficiency is challenged directly by a sophisticated method: co-extrusion. We are the first in JiangSU XINHE Intelligent Equipment Co., Ltd to introduce this advanced smart technology into high performance, automated production lines that help transform the way manufacturers will produce high quality products in the form of pipes.

Beyond Single-Layer: The Strategic Advantage of Co-extrusion

Co-extrusion has proven to be strategically beneficial beyond single layer designs. Co-extrusion entails simultaneous extrusion and bonding of two or more layers of entities of different materials using application of a single die to produce an integrated product. In HDPE pipes, we usually use it in a two-layered design:

A Primary Layer (Core): Which is formed of a high grade, often black, HDPE compound with carbon black to give it good long term hydrostatic strength and UV coverage.

A Functional Layer: Which can be a thin, bright coloured HDPE layer as a visual indicator such as yellow to indicate gas or blue to indicate water, or a compound with special properties, such as antimicrobial behaviour or low permeability. What we are pointing out here is that this type of multi-layer is not a mere lamination as such but rather a molecular marriage upon extrusion to form a monolithic pipe that has clearly defined well-purposed strata.

Xinhe's Engineered Solution: Precision for Small-Diameter Excellence

The application of co-extrusion to small-diameter pipes in the 725 mm range offers special difficulties and we know that extraordinary accuracy of material handling, laying, and cooling is needed. The production lines of Xinhe are carefully designed such that we are able to handle such demands with ease.

The Synchronized Extrusion System

In the heart of our solution we implement a coordinated extrusion system which relies on two identical single screw extruders. One extruder will be used in the new manufacturing process of the primary HDPE material, and the other will be used in the colored or functional HDPE layer. We achieve this with our sophisticated drive and control system whereby the extruders have the same melt pressure and output; we also know this is critical in maintaining a consistent concentric layer thickness. In the case of small diameters, we consider this an indispensable condition of long-term durability of the pipes.

Advanced Co-extrusion Die & Spiral Distribution

The technology is based on an exclusive co-extrusion spiral die of Xinhe. Our advanced tool was developed to combine the two melt streams without any form of error. Spiral mandrel system lays every material uniformly on the circumference and then the materials join and we make sure that the thin outer functional coating is perfectly concentric and uniform in thickness as thin as 0.2 0.5 mm around the whole pipe. It is this degree of accuracy that we avoid weak points and ensure a dependable performance in hard situations.

Integrated Benefits for Manufacturers

Implementation of the Xinhe co-extrusion line brings in the benefits of transformation:

Material & Cost Optimization: Another way to save a considerable amount of costs is by using less expensive primary compound in the majority of the wall thickness and only the more expensive colored or specialty material in the thin and necessary outer plating.

Enhanced Product Quality & Compliance: The pipe is in compliance with all or even higher international standards (ISO, DIN, ASTM) of pressure rating and durability. The colored layer is fully integrated and non-fade identification to ensure the safety and compliance without requiring the processes of post-extrusion painting or tape.

Superior Production Efficiency: The production line uses one continuous, automated production to come up with a finished, code compliant pipe. This simplifies the production process, labor and the complexity of the inventory in terms of holding stocks of pre-colored compounds in different pipe types when compared to the situation of having individual stocks of recolored compound.

Process Stability & Yield: Our vacuum calibration and closed-loop cooling tanks provide the reliability in terms of the accurate sizing and fast solidification of the multi-layer structure that leads to good dimensional accuracy, perfect surface finish, and low scrap levels.

We give a single, continuous, automated process of producing an all-code compliant-cut pipe. We operate more efficiently, cut down on the number of labor and minimize inventory complexity to the maintenance of multiple stocks of pre-coloured compounds. Simultaneously, we maintain the stability of processes and high yields with a combination of vacuum calibration and closed-loop cooling tanks which size and solidify the multi-layer structure with a high rate. We get high dimensional components, superior surface finish and low scrap rate as a by product.

Conclusion: Setting a New Standard in HDPE Pipe Manufacturing

To sum up, we do not think the results can be called the smart and modern manufacturing standard whenever every micron of wall thickness and every material characteristic matters, which is the case with diameters 7 mm to 25 mm. It is no longer a choice, but a strategic instrument by manufacturers who are out to be the best in their quality, efficiency and marketability.

The products and services of Jiangsu Xinhe Intelligent Equipment Co., Ltd. are not only machines but also represent a turnkey production offering that is a measure of our patented engineering, comprehensive knowledge of the process, and our continued investment in an innovative offer. When we select the co-extrusion line of Xinhe to investing with, we assist you to invest in a system that is capable of producing high-quality HDPE pipes that characterize reliability, safety, and full competitive advantage.

You are ready to take the next level in the HDPE pipe production with co-extrusion technology? You can call us now at Jiangsu Xinhe and see how our 7-25 mm customized solutions can be used to make you successful in such a challenging market.