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September 2013

HIGH ACCURACY IN MEDICAL TUBING NEW WAY TO INSPECT WELD JOINTS PIPE DIES BRING PROCESS SAVINGS K2013: PREVIEW OF THE BIG SHOW


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contents PAGE 5

05 Industry news Orders rise for German machinery; @PlasticsWorld attracts 5,000 Twitter followers; GF Piping sales up, profits flat; Deceuninck boosts pultrusion in North America; Pexco buys Scandia

11 K2013: Materials preview

PAGE 11

With K2013 just six weeks away, we kick off our preview of the show with a look at new materials, including both resins and additives. Lou Reade reports

19 K2013: Ancillaries preview Ancillaries are the supporting cast of the plastics industry, and the forthcoming K2013 will see plenty of new offerings to choose from. Lou Reade reports

27 Volumetric inspection of welded joints in PE pipe

PAGE 19

A new way of inspecting weld joints could see polyethylene pipe being used in a wider range of applications, says Mike Troughton of TWI

33 Taking the tube While medical tubing is getting ever smaller, the need for accuracy during production is increasing. Lou Reade reports

39 In the round PAGE 27

Improving the energy efficiency of pipe dies and pipe heads can bring significant savings to the extrusion process

43 Taking the strain Pressure pipes come in many different forms, from oriented PVC to fibre-reinforced composites

PAGE 33

47 Technology: Materials 48 Technology: Machinery 52 Extruder of the month: Reschcor 54 Dates for your diary

coming next issue ❙ Extruder technology ❙ Downstream equipment ❙ Trenchless pipe installation ❙ K2013 show issue ➤ Click here to make sure you get your copy

contact us Applied Market Information Ltd AMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United Kingdom Tel:+44 (0)117 924 9442 Fax:+44 (0)117 989 2128 www.amiplastics.com

Head of business publishing: Editor: Senior editor: Designer: Advertisement manager:

Andy Beevers Lou Reade Chris Smith Nicola Crane Claire Bishop

E-mail: abe@amiplastics.com E-mail: lou@pipeandprofile.com E-mail: cs@amiplastics.com E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139

© Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher. www.pipeandprofile.com

September 2013 | PIPE & PROFILE EXTRUSION

3


16-23 October D端sseldorf Hall 09 A60


news

Orders rise for German machinery

GF Piping sales up 3% for first half of 2013

Orders for German plastics

GF Piping Systems, the pipe

and rubber machinery have

manufacturing division of Swit-

picked up, though still lag

zerland’s Georg Fischer,

behind last year.

reported a 3% rise in sales for

Trade association VDMA says that orders rose by

the first half of this year. But while sales moved

14% in the second quarter

ahead to CHF665m ($715m),

of 2013, but the first half

operating profits remained

still shows a 6% decline.

static at around E67m.

“In the last three

“An unusually long winter

months, incoming orders

dampened construction and

have picked up again,” said

investment across Europe and

Ulrich Reifenhäuser, VDMA

parts of the US until April,”

chairman.

said the company.

Sales for the first half of

GF Piping’s May 2012 acquisition of IPP in the US had a positive effect on this year’s results

However later in the year it

2013 matched those of

benefited from its May 2012

Hakan Plastik, a Turkish pipe

sales reached CHF1,837m

2012, while sales for the

acquisition of IPP in the US.

manufacturer with a turnover

($1974m) for the first half-year

exceeding CHF100m ($107m).

of 2013, which was slightly

America rose this year, and

It says that the acquisition

lower than in the previous year.

together accounted for almost

gives it a stronger presence in

However, operating profits

55% of turnover (against 50%

the Middle East and Eastern

were up 3%, despite the low

last year).

Europe.

utilisation of several European

second quarter were 6% ahead of last year. Foreign sales also took an upward turn. “From March to May foreign deliveries rose by

Sales in Asia and North

“Water treatment demand is

“The acquisition will bring

plants.

9.7%,” said Thorsten

steadily growing, semiconduc-

additional turnover and profit

At the same time, the

Kühmann, VDMA managing

tor applications picked up again

during the second half-year,”

company reduced headcount

director. “The upward trend

and the key building technology

said the company.

by 400: a reduction in 700

in exports to Russia and the

markets of GF Piping Systems

US continued, with China,

continued to perform well,”

of a CHF25m cost reduction

partly offset by a rise in

India and Turkey also

said the company.

plan should be visible later this

employees in Asia and North

showing growth.”

❙ http://kug.vdma.org

Georg Fischer has also completed its acquisition of

At the same time, the effects

year and in 2014. Overall, Georg Fischer’s

European employees was

America.

❙ www.gfps.com

Pexco expands by acquiring Scandia extrusions and a similar

US-based plastics extruder

which supplies rigid extruded

Scandia was founded in 1971

Pexco has expanded its

tube casings to the industrial

by Dave Hallett, who will remain

commitment to downstream

operations by acquiring

and life science filtration

as the company’s president of

operations.”

Scandia Plastics.

markets.

site operations. The company

It is the company’s first

Neil Shillingford, Pexco

Pexco is based in Atlanta,

has a 62,000 sq ft facility in

and has 10 plants in the US

acquisition since it was bought

CEO, said: “Scandia is a

Plaistow with 12 production

and Mexico. It provides

by private equity firm Odyssey

perfect fit for our business – a

lines and around 50 employees.

standard and speciality parts

Investment Partners in August

classic speciality extruder

“This is the right move for

and components for applica-

of 2012.

bringing value to its customers

Scandia Plastics,” said Hallett.

tions including aerospace, industrial, commercial,

through high performance

“Pexco and Scandia comple-

extrusion business based in

extrusion processing and

ment each other well,

medical and life science.

Plaistow, New Hampshire,

value-added finishing.”

emphasising performance

❙ www.pexco.com

Scandia is a custom

www.pipeandprofile.com 

September 2013 | PIPE & PROFILE EXTRUSION

5


news

Naylor adds flexible ducting

Deceuninck expands pultrusion in N America

UK-based Naylor Drainage

Deceuninck North America has

company of Graham Engineer-

president and CEO of Deceun-

has acquired plastic

taken over the pultrusion assets

ing, manufactures architectur-

inck North America. “This

extrusion business Amco

and related intellectual property

al-grade windows, doors and

expands our capability to offer

Plastics.

of Graham Engineering.

curtain wall.

products with superior

Amco Plastics, which

Deceuninck will also

“Through this acquisition,

strength and increased energy efficiency.”

has a turnover of £4.4m

become the exclusive supplier

Deceuninck is securing its spot

($6.8m), makes plastic

of pultruded polyurethane (PU)

as a leader in this important

extrusions and flexible

window components to

market sector, which has

Innergy rigid thermal reinforce-

ducting for sectors

Graham Architectural

specific relevance to our

ments and hybrid window and

including leisure, cable,

Products (GAP) for its GThurm

residential customers as well

door systems, which are based

flooring, DIY, mining and

composite window and curtain

the commercial construction

on pultruded polypropylene.

tunnelling.

wall systems. GAP, a sister

industry,” said Filip Geeraert,

❙ www.deceuninck-americas.com

He cited the company’s

It was set up to supply ventilation ducting to the domestic mining and tunnelling industries, and

Micro-extruder for fluoropolymers

has since diversified into

American Kuhne has developed a 16mm micro extruder to

plastic extrusions. The

process fluoropolymers for miniature medical device applications

company now has nine

such as neonatal intravenous (IV) catheter tubing. They typically

extrusion lines offering

need an extruder that can process fluoropolymers like ETFE, PFA

both rigid and flexible tubes

and FEP at volumes down to 3.4g/min (0.45lbs/hr).

and profiles including cable

It is usually difficult to process fluoropolymers on extruders

fillers and floor profiles. It

smaller than 16mm because the corrosion-resistant screws have

also has a fabrications

low torsional strength. The smallest extruders for these applica-

department that offers

tions have traditionally been 19mm machines. The benefit of a

laminating, slotting and

16mm extruder is a 45% reduction in the minimum output rate

abrasive surface treatment

and a short residence time in the barrel.

services.

l For more medical tubing technology, see page 33.

❙ www.naylor.co.uk

❙ www.americankuhne.com

Nordson is acquiring Kreyenborg and BKG Nordson of the USA is acquiring the plastics process-

year were around E62 million. Jan-Udo Kreyenborg and

complementary to our other

company acquired US-head-

recent acquisitions in the

quartered Xaloy, which is best

ing activities of the Kreyenborg

Theodor Bruckmann are

polymer processing space and

known for its screws and

Group of Germany. The deal

retiring as directors of the two

fit our strategy of providing our

barrels, but also makes

includes two companies - BKG,

companies following the sale

customers with high-value,

screen-changers, melt pumps

which produces pelletising

of their shares. Jan Hendrik

mission-critical melt stream

and pelletising systems.

systems, and Kreyenborg

Ostgathe and Ralf Simon who

components that will enhance

GmbH, which makes screen-

already hold managing

the performance of their

chased two manufacturers of

changers and melt pumps.

director roles will continue in

systems.”

flat extrusion dies in recent

The two companies employ approximately 270 people and

these positions after the change in ownership.

Nordson, which is a leader in dispensing systems, has

Nordson has also pur-

years – US-based EDI in 2012, and Belgium-based Verbrug-

recently been increasing its

gen in 2011.

China, Malaysia and the USA.

CEO, Michael Hilton said:

activities in plastics processing

Revenues for the 2102 fiscal

“These businesses are highly

equipment. Last year, the

❙ www.nordson.com ❙ www.kreyenborg.com

have additional operations in

6

Nordson’s president and

PIPE & PROFILE EXTRUSION | September 2013

www.pipeandprofile.com


Visit our booth at K’2013 in Dßsseldorf, Germany, Hall 09 / C59


news

@PlasticsWorld attracts 5,000 Twitter followers

JM Eagle case starts this month

@PlasticsWorld, the Twitter

stories on a regular basis, and

as delivering news about our

The ‘whistleblower’ case

page for AMI’s magazines,

they will be providing real-time

comprehensive programme of

against US pipe manufac-

publications and events, has

reporting from the forthcoming

plastics industry conferences.

turer JM Eagle is finally due

now attracted more than 5,000

K 2013 exhibition.

followers from around the

Our 5,000+ Twitter followers

If you already have a Twitter account, then you can follow

to start this month. The trial will begin on 17

globe, making it one of the

are also the first to be notified

and contact us at @Plastics-

September at the Central

most influential Twitter feeds

when we publish a new issue

World. If you want to set up

District of California,

for the international plastics

of one of our five digital

your own personal or company

Western Division court,

industry.

magazines: Compounding

Twitter account, then it’s quick,

under district judge George

World, Film and Sheet

easy and free (there is a useful

Wu.

page is used to announce

Extrusion, Injection World,

guide to setting up a corporate

plastics industry news as it

Pipe and Profile Extrusion and

account at http://bit.ly/

back in 2006, and has been

happens, providing useful links

Pipeline Coating. In addition,

CorpTwitter). Those without a

delayed several times since

to relevant web pages,

the @PlasticsWorld Twitter

Twitter account can still view

the trial was scheduled to go

documents, images and

page is used to announce

our Tweets using the URL

ahead more than a year ago.

videos. Our expert editors and

special discount offers on our

below.

journalists add breaking news

books and publications, as well

❙ www.twitter.com/plasticsworld

The @PlasticsWorld Twitter

The case was first filed

Former JM Eagle employee John Hendrix alleges that the company

Electrical conduit standard updated

deliberately used substandard material to make defective PVC pipe, which

The Plastics Pipe Institute

was then used in construc-

(PPI) and the National Electric

tion projects across the US.

Manufacturers Association

JM Eagle denies the

(NEMA) have revised the TC 7

charges, but will now face

standard for coilable electrical

charges under the False

polyethylene conduit.

Claims Act. Whistleblower or ‘qui

Members of the PPI’s conduit division helped to

tam’ cases are a common

revise the standard – NEMA TC

feature in the US, and allow

7-2013, ‘Smooth Wall Coilable

private citizens to sue

Electrical Polyethylene

companies that are

Conduit’, made from high-

defrauding government entities, and recover

density polyethylene (HDPE) – to bring it up to current

The TC 7 standard for coilable electrical polyethylene conduit

damages on the govern-

industry requirements.

has been revised

ment’s behalf. A number of ‘govern-

TC 7 includes trade sizes ranging from 0.5in to 8in

the conduit during installation

istics of Plastic Pipe by

ment entities’ – including

diameter. In addition, there are

and service life.

Parallel-Plate Loading’.

two US states and a number

five electrical polyethylene

There are two main

At the same time, the

of Californian cities and

conduit (EPEC) wall types.

changes for testing in the

traditional ‘crush test’ has

water authorities – have

latest version of TC 7. Firstly, a

been changed to a visual pass/

joined the case against JM

provides end users with a

new test for pipe stiffness has

fail and recovery test for

Eagle, though several

wider range of diameters and

been added to the standard

evaluating the finished

others have either dropped

wall options that can be

conducted in accordance with

conduit’s ductility.

out or declined to join

matched to the specific

ASTM D 2412, ‘Determination

(including the US Govern-

physical loads to be placed on

of External Loading Character-

❙ www.plasticpipe.org ❙ www.nema.org

The new version of TC 7

8

PIPE & PROFILE EXTRUSION | September 2013

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EXTREME EXPERIENCES AT K 2013!

Take a trip to a new level at K 2013. Experience the high-speed injection molding of high-quality electrically-conductive plastic compounds based on carbon black. The benefits of Premix’s high-flow PRE-ELEC® PP compound will be demonstrated on the Arburg stand (13/A13) in a state-of-the-art application developed in conjuction with Arburg, Tanner and Waldorf. Don’t miss out on this ground-breaking live demonstration. We are at K 2013 for you. Visit us at Premix stand 08a/K27. Share your challenges with our team and your problems will be solved! Book an appointment: eira.karja@premixgroup.com

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Materials |

2013 preview

With K2013 just six weeks away, we kick off our preview of the show with a look at new materials, including both resins and additives. Lou Reade reports

Making the most of materials Materials have never been as prevalent as machinery at

which also exhibits better performance in terms of heat

the K show: just look at the number of halls devoted to

ageing. S4Z4 XS grade has optimised zinc chloride

the two, and you’ll see that machinery is the dominant

resistance.

force. Of course, this is partly because machines (especially extrusion lines) take up so much space. But despite this imbalance, there are plenty of reasons

applications require other polymers because of more demanding thermal stability and fuel permeation requirements. Here, the properties of the PA610 and

materials – or simply keep abreast of what’s available.

PA12 materials complement one another, says BASF. The mechanical properties of PA610 can be custom-

include two flexible extrusion grades of Ultramid S

ised by altering the formulation. As a result, the

Balance.

products compete with PA12 in terms of flexibility,

The materials, Ultramid S4Z5 Balance and S4Z4 XS

be achieved, a typical specification for tubing systems in

quantities from November 2013. They are suitable for

cars. A melting point of 222°C helps Ultramid S Balance

making pipe and tubing for the automotive and

to meet continuous-use and peak temperature

machinery sectors, as well as oil and gas lines.

demands, exceeding that of PA12 (with a melting point

lines that satisfies demanding temperature require-

fabric-reinforced silicone hoses for automotive applications

of 178°C). The stress cracking resistance of PA610 falls

ments, while S4Z4 XS is a very flexible product for

between that of PA66 and PA12. Ultramid S Balance can

vacuum and vent lines, and has even greater resistance

be used in parts that come into contact with solutions

to stress cracking.

containing CaCl2 (as road salt in cold climates) and

The formulations of both compounds use a highly

used to make

stiffness and toughness. Elongation of up to 200% can

Balance, will be seen at K2013, and available in sample

S4Z5 is a semi-flexible grade for liquid-conveying

from Wacker’s Elastosil are

Polyamide extrusion is dominated by PA12, but other

for visiting K2013 if you are looking to source new BASF has expanded its PA610 line of products to

Hoses made

ZnCl2, which can be encountered on zinc-coated parts.

viscous polyamide 610 that is further modified to

Stress peaks can be avoided in tubing systems by using

achieve good low-temperature impact strength. The

welding solutions as an alternative to the classical

soft S4Z4 XS produces very flexible tubing, which

retaining ribs of the fitting.

simplifies installation. The products differ in terms of their stiffness and toughness. The burst pressure and

Top class

fitting retention force are higher for the S4Z5 grade,

Borealis will showcase a number of polyolefin pipe

www.pipeandprofile.com

September 2013 | PIPE & PROFILE EXTRUSION

11


2013 preview | Materials

Baymod N XL

grades at K2013,

good green strength. It is aimed at applications such as

33.61 from

including a new

extruding oil-resistant rubber profiles and calendering.

Lanxess can

version of its

improve the

crosslinkable PEX-a

profiles is the relatively high die swell of conventional

surface quality

compound.

nitrile rubber,” said Robert Stäber, a synthetic rubber

of extruded

It is relaunching its

“The challenge NBR users are facing when extruding

expert in the high performance elastomers business at

PVC

enhanced HE1878E-C2,

Lanxess. “Using pre-crosslinked rubber helps make

products

claiming it is the first

this less of a problem.”

fully-stabilised,

The material reduces die swell by up to 80%, he says.

ready-compounded

Another benefit is that pre-crosslinking stabilises

PEX-a to achieve Class 5

the unvulcanised profile, so the material is ideal for

listing. The Class 5 listing

making products with a complex cross section.

corresponds to the highest

nitrile rubbers as a versatile additive to enhance

in accordance with the

properties. Lanxess has added to its portfolio of powder

ASTM F876 standard for PE

NBR additives with the pre-crosslinked NBR Baymod N

crosslinked pipes using the ASTM F2023 test method. ASTM F876 is the standard specification for PEX tubing in North America. The advanced qualification of Borealis HE1878E-C2 opens up a new range of opportu-

blends that are characterised by good elasticity and

tion, says the company.

exceptional ozone and weathering resistance, for

systems for hot

NBR can also improve the low-temperature flexibility and oil resistance of the plastic and ease extrusion of

pound, the material also offers significant production

the material. “Even at proportions of around 20% in the PVC

minimising the risk of additive dosing errors; it is easy

matrix, it produces smooth, high-quality surfaces that

to handle; and its cost efficiency is also improved.

can stop PVC looking like a ‘cheap plastic’,” he said.

At the same time, its polypropylene random crystalline temperature (PP-RCT) has been included in the updated EN ISO 15874, the global standard for installations.

standard for

example.”

flexibility and low creep. As a mini-pelletised com-

plastics piping systems for hot and cold water pipe

plastics piping

“Due to their polarity, nitrile rubbers with a medium to high acrylonitrile (ACN) content can easily be mixed said Stäber. “The spectrum extends to proper PVC/NBR

in the updated the global

overcome problems with some plasticisers.

to gain a competitive edge thanks to product differentia-

been included EN ISO 15874,

surface quality of extruded PVC products, and help to

with PVC in high proportions and add new properties,”

advantages: it requires only the addition of peroxide,

Borealis has

One of its advantages is that it can improve the

nities for pipe producers in North America, while

The PEX-a pipe boasts benefits such as enhanced

material from

XL 33.61.

enabling producers in Europe, Asia and the Middle East

durability, high temperature resistance, excellent

PP-RCT

At the same time, the PVC processing industry uses

chlorine-resistance rating

The materials contain a high level of beta-nucleated crystals and an advanced stabilisation package, allowing operation at higher stresses at elevated temperatures, opening up applications such as large diameter pipes for skyscrapers.

and cold water

“Designers and installers are increasingly seeing the

pipe

vast benefits achievable with PP-RCT pipes,” said Anton Wolfsberger, marketing manager for energy & infrastructure at Borealis.

Rubber benefits Lanxess will show a number of new rubber grades at K2013. Its new pre-crosslinked nitrile rubber (NBR) Krynac XL 3355 VP exhibits low die swell, a smooth surface and 12

PIPE & PROFILE EXTRUSION | September 2013

www.pipeandprofile.com


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• Flexible installation: optional floor stand enable to swivel upwards by 110° of the measuring head, allowing quick and easy working access when needed • Interfaces: RS, Profibus, Profinet, Ethernet, J for USYS systems from Zumbach MSD models are available for products up to 200 mm (8 in.) outside diameter.

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2013 preview | Materials

BASF has added two flexible extrusion

It can also help the user to reduce the use of phthalate-containing plasticisers. Combined with its Mesamoll plasticiser, it is possible to largely dispense with both DOP and DINP

grades to its Ultramid S Balance range if polyamide 610

TPE restructuring At K2013, Teknor Apex will introduce a restructuring of its thermoplastic elastomer (TPE) brands that will enable it to serve as a single source of multiple compounds for European plastics processors in a diversity of industries. All TPEs applicable to a particular end-use sector will be grouped under a single brand, regardless of how widely the compounds differ in terms of polymer chemistry. This includes many of its TPEs developed in the US and previously unavailable in Europe. For example, its Sarlink brand has been expanded beyond thermoplastic vulcanizate (TPV) to include styrenic and olefinic blends – which until now were produced only in the US. The material is commonly used for automotive applications such as window seals. “Sarlink represents a complete solution for the transportation market,” said Ger Vroomen, senior automotive market manager. “For designers of automotive sealing systems, in

PE100-RC pipes were welded seamlessly into one long

particular, Teknor Apex can provide a TPV or styrenic

section and were ideally suited to be pulled below

compound as an alternative to EPDM rubber, depending

ground through the existing pipe.”

on customer requirements.” Other restructured TPE brands include: Elexar

Marc van den Berg, business manager for infrastructure and construction at Total, said: “Once installed,

elastomers for electrical and electronic applications,

pipes made with our PE are corrosion-free and

such as insulation and jacketing of power, communica-

designed to last for at least 100 years.”

tions and data cables; and Medalist medical elastomers, which range from range from a gel-like 25 Shore

Automotive hosing

00 to a ductile 85 Shore D. Clear and are used for,

Wacker will exhibit a new grade of silicone rubber that

among other things, extrusion of tubing, profiles, films

enables cost-effective extrusion of fabric-reinforced

and wire coating.

silicone hoses. Hoses made from Elastosil R 416/70 are

Total will showcase a range of products at K2013, including several material grades for making pipes. One of them, XSene XSC50, was recently used in a

temperature and coolant resistance. The peroxide-curing material has been developed for

pipeline in South Africa. Pietermaritzburg, the capital of

extrusion of hoses. It boasts superior green strength

KwaZulu-Natal province, switched to high density

and a non-sticky surface. As a result, uncured ‘endless’

polyethylene (HDPE) to replace 2km of old, leaking

hose blanks retain their shape during post-processing.

metal pipes. The existing water mains were replaced

As it cures, the material adheres well to fabrics,

without excavation, by bursting the old metal pipes and

forming a strong bond that leads to hoses with high

replacing them with Wavin TS DOQ pipes, made from

pressure resistance.

XSene XSC50. Total’s latest generation of HDPE pipes rely on its

When cured, the material has heat resistance at temperatures up to 210°C, flexibility at temperatures

PE100-RC (resistance to crack) grades, including both

down to -45°C, high ageing and continuous fatigue

XSC50 and XRC20.

resistance. It is also sufficiently resistant to the glycol-

“The PE100-RC concept was developed in partnership between our companies and we have used it

14

aimed at automotive applications that demand good

water-based coolants used in the automotive industry. A sample application of the new product is the

extensively in our Wavin TS DOQ pipes,” said Ralf

production of coolant hoses for turbochargers in which

Glanert, product manager at Wavin. “In this project, the

the bearing housing is cooled. This is commonly the case

PIPE & PROFILE EXTRUSION | September 2013

www.pipeandprofile.com


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Tecnomatic Srl | Bergamo | Italy | tel. +39 035 310375 | www.tecnomaticsrl.net


2013 preview | Materials

polymer additive solutions – at K2013. It comprises two strands: AddWorks, which are application-oriented solutions specifically designed for different segments of the plastics industry; and AddWorks LXR, a new range of polymer additives designed to provide particular effects in a variety of applications. AddWorks tailored formulations can provide multiple benefits, such as improved productivity, stability and durability of converted parts, or protection of manufactured articles during their process; says Clariant. “AddWorks is about making it simple for customers. We want to provide a solution that works and fits their needs,” said Ernesto Dongiovanni, head of marketing for polymer additives at Clariant. A new

in engines that use the Otto cycle. In turbocharger

crosslinked

coolant hoses, the glycol-water mixture is fed from the

Shifting to octyl tin

nitrile rubber

radiator to the turbocharger’s bearing housing and back

Songwon, the Korean additives supplier, has increased

from Lanxess

again.

production of DOTO (Dioctyl Tin Oxide) as it shifts

exhibits low die swell

Elastosil R 416/70 is also suitable for making hoses

production of its heat stabilisers from butyl tin to octyl

for differential pressure sensors in diesel particle filters.

tin. The company expects to replace butyl tin completely

These sensors measure the difference in pressure

by 2015, due mainly to the demands of Europe’s Reach

between the two sides of the filter, providing information

legislation.

about the filter’s particle load. The hoses mechanically decouple the sensitive sensors from the exhaust pipe. Hoses made from the material are superior to conventional rubber hoses in a number of engine-relat-

It is boosting DOTO capacity by 60% at its Ulsan manufacturing facility in Korea. At the same time, production of DBTO (Di-n-Butyltin Oxide) will reduce. Beyond this project, Songwon is planning additional

ed applications, says Wacker.

DOTO capacity to support future market needs.

Additive extensions

and intermediates, marketed under the brand Songcat,

As well as polymer materials, there are also a number

and Organotin heat stabilisers marketed under the

of developments on the additives front, especially in

brand Songstab.

Songwon is a leading producer of organotin catalyst

PVC stabilisers.

The organotin intermediates are used as raw

Baerlocher will showcase its range of additives

materials in the production of heat stabilisers. Song-

– including Ca-based heat stabilisers for PVC produc-

won’s brand of heat stabilisers is mainly used in PVC

tion, as well as many other products for making

and styrenic applications.

profiles, pipes, cables, floor coverings and film. Its 140 sq m stand at K2013 has been designed by

KT Jeong, Songwon’s business manager for PVC stabilisers and tin intermediates, said: “Songwon has

Wroom, a young team of architects and designers who

been a leader in complying with environmental

are all graduates of the State Academy of Fine Arts in

regulation. Our move to DOTO will ensure that we can

Stuttgart.

provide the products that our customers need without

“Baerlocher’s idea to break new ground enabled us

compromising our environmental stewardship.”

to design a new booth from scratch,” said Philipp Münster of Wroom. “It visualises the theme of Baer-

Click on the links for more information:

locher and translates it into a filigree, molecule-like

❙ www.basf.com ❙ www.borealisgroup.com ❙ www.lanxess.com ❙ www.teknorapex.com ❙ www.total.com ❙ www.wacker.com ❙ www.baerlocher.com ❙ www.clariant.com ❙ www.songwon.com

structure that is also functional.” The company says it is growing its presence in emerging markets such as China, India, Russia, Turkey and the Middle East. “Due to its international orientation, the K show is the ideal platform for us,” said Arne Schulle, CEO of Baerlocher. Clariant will launch AddWorks – its new brand for 16

PIPE & PROFILE EXTRUSION | September 2013

www.pipeandprofile.com


Rich Yu Chemical

A global leader in polymer additives Rich Yu has extensive facilities for producing a wide range of polymer additives in Taiwan and it is expanding its capacity with the construction of a new plant. The company has a global supply network, including a warehouse in Rotterdam, and it exports 80% of its production worldwide. It has obtained ISO 9001 and ISO 14001 certification, as well as FDA , JOSHPA and REACH compliance.

l High-performance antioxidants Richnox hindered phenols Richnox thioesters Richfos phosphites and liquid phosphites Richnox B binary blends l UV absorbers and light stabilizers Richvin HALS series Richvin and Richsorb UV absorbers l PP clarifiers and nucleators l Curing agents l Metal deactivators l Preblends l Other special polymer additives

www.richyu.com.tw No. 61, Industrial RD., Nan-Kang Industrial Zone, Nan-Tou City, 540, Taiwan, R.O.C. Tel: 886-49-2261928 Fax: 886-49-2257072


AMI’s Directory

New 2013

PLASTICS PROCESSORS IN POLAND LOCATION & PRODUCTION DETAILS OF 1100 PLASTICS PROCESSING PLANTS

6th edition

AMI’s Directory

PLASTICS PROCESSORS IN POLAND

3E SP. Z O.O.

Polymers, products & machinery

Type: Custom, Proprietary Products Polymers processed: PS, ABS, LDPE, HDPE, PP, PMMA, PC, ASA. Polymer throughput: Less than 50 tonnes Markets served: Automotive, Electrical, Alarm Cases. Services offered: Pad Printing, Silk Screen Printing Number of machines: 4 Minimum lock: 120 Maximum lock: 268 Minimum shot: 5 Maximum shot: 600

LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS

Address Listing

AMI’s Directory of Plastics Processing in Poland

A KAYSER AUTOMOTIVE SYSTEMS POLSKA SP. Z O.O. Type: Custom Polymers processed: PS, HDPE, PP, PA Polymer throughput: Between 251 - 500 tonnes Markets served: Automotive, Very Small Car Components (Fuel & Air Ducts; Filters & Valves). Services offered: U/S Welding, Friction Welding, Assembly Number of machines: 15 Minimum lock: 60 Maximum lock: 200 Minimum shot: 15 Maximum shot: 427

3E SP. Z O.O.

A. SCHULMAN POLSKA Sp. z o.o.

ul. OkrĊĪna 1B 19-300 Eák Tel: 087 620 1630 Fax: 087 620 1630 E-mail: a.sznelinska@3E.net.pl Website: www.3E.net.pl Contact: Mr. Z. Hoádyk, Plant Manager

ul. Nowa Biaáa 37 09-411 Biaáa k/Páocka Tel: 024 364 0012 Fax: 024 364 0011 E-mail: aschulman@pl.aschulman.com Website: www.aschulman.com Contact: Mr. A. Rozalski, General Manager

Parent company: Privately Owned

Parent company: A. Schulman Inc., OH

ABA PPH SP. Z O.O.

Processes operated: Injection moulding

Processes operated: Compounding

3P SYSTEM SP. Z O.O.

ABA PPH SP. Z O.O.

ul. Aleja Jana Pawáa II 94 Sáupno 05-250 Radzymin Tel: 022 786 6149/763 2820 Fax: 022 786 5357 E-mail: 3psystem@3psystem.com.pl Website: www.3psystem.com.pl Contact: Mr. W. GoáĊbiowski, Chairman

ul. PoznaĔska 132 62-052 Komorniki Tel: 061 810 7785 Fax: 061 810 8276 E-mail: biuro@aba.pl Website: www.aba.pl Contact: Mr. S. Zielaskowski, Owner

Type: Custom Polymers processed: LDPE, HDPE, PP Polymer throughput: Between 251 - 500 tonnes Markets served: Medical/Pharmaceutical, Caps and Closures, Medication Measuring Spoons. Services offered: Printing on Closures.

Parent company: Privately Owned ISO registration: ISO 9001v2000 Processes operated: Sheet extrusion

A I B. SPOLKA Z OGRANICZONA ODPOWIEDZIALNOSCIA S.K.A. ul. Przemysáowa 22 44-190 Knurów Tel: 032 335 7900/10 Fax: 032 335 7905 E-mail: firma@aibsc.com.pl Website: www.aibsc.com.pl Contact: Mr. M. ĝlączka, Co-owner

Addresses & contacts

Parent company: Privately Owned ISO registration: ISO 9001v2008 Processes operated: Injection moulding

ABET SP. Z O.O. ul. Klonowa 3 05-806 Komorów k/ Warszawy Tel: 022 759 1140 Fax: 022 759 1140 E-mail: info@bet.com.pl Website: www.bet.com.pl Contact: Mr. A. Bieluszko, Owner Parent company: Privately Owned

Parent company: Privately Owned ISO registration: ISO 9001.

Processes operated: Injection moulding

Processes operated: Profile extrusion

ul. 1 Maja 14a 78-400 Szczecinek Tel: 094 374 0114 Fax: E-mail: abex@abex.pl Website: www.abex.pl Contact: ,

A KAYSER AUTOMOTIVE SYSTEMS POLSKA SP. Z O.O. ul. SkoĞna 16 Batorowo 62-080 Tarnowo Podgórne Tel: 061 665 0300/308/314/315 Fax: 061 665 0317 E-mail: polen@kayser-automotive.com Website: www.kayser-automotive.de Contact: Mr. R. Jakubiak, Managing Director

Injection moulders

AMI’s Directory of Plastics Processing in Poland

ABET SP. Z O.O.

Type: Custom Polymers processed: PS, LDPE, PP Polymer throughput: Less than 50 tonnes Markets served: Household, Clothes Hangers. Services offered: Hot Foil Stamping Number of machines: 10 Maximum lock: 20 Minimum shot: 30 Maximum shot: 200

ABEX SP. Z O.O. Type: Custom, Proprietary Products Polymers processed: PS, ABS, PP, PA, PC, PET Polymer throughput: Between 101 - 250 tonnes Markets served: Electrical, Electrical Connectors Services offered: Assembly Number of machines: 11 Minimum lock: 60 Maximum lock: 160 Maximum shot: 200

ACAR S.A.

Type: Custom Polymers processed: PVC Polymer throughput: No Polymer consumption available Markets served: Electrical, Sockets and Plugs.

ACE LUXE Type: Custom, Proprietary Products Polymers processed: ABS, PC, Elastomers. Polymer throughput: Between 1001 - 1500 tonnes Markets served: Telectron Services offered: Assembly Number of machines: 13 Minimum lock: 270 Maximum lock: 850 Maximum shot: 2500

AC-WYTWÓRNIA CZĉĝCI SAMOCHODOWYCH S.C. Type: In House Polymers processed: PS, ABS, LDPE, HDPE, PP, PVC, PA Polymer throughput: Less than 50 tonnes Markets served: Automotive, Car Components. Services offered: Tool Design, Tool Manufacture, Pad Printing, Assembly, Machining Number of machines: 6 Minimum lock: 25 Maximum lock: 90 Maximum shot: 500

AGD PASTERSKI SP. J. Type: Proprietary Products Polymers processed: PS, LDPE, HDPE, PP, PET Polymer throughput: Between 101 - 250 tonnes Markets served: Household, Chopping Boards; Brushes. Number of machines: 20

AGFOL PRZETWÓRSTWO TWORZYSZ SZTUCZNYCH S.C. Type: Custom, In House Polymers processed: LDPE, HDPE, PP Polymer throughput: Less than 50 tonnes Markets served: Household, Furniture Components; Components for Candle Lamps. Number of machines: 3 Minimum lock: 100 Maximum lock: 160 Minimum shot: 80 Maximum shot: 240

ABEX SP. Z O.O.

197

Parent company: Privately Owned Processes operated: Injection moulding

Parent company: A Kayser Automotive GmbH, Germany ISO registration: ISO 9001v2000

Available as a fully searchable database

Processes operated: Injection moulding

18

Over the past decade polymer consumption has grown on average by 4% per year in Poland Make sure you know all about this dynamic industry

Companies included: • Injection moulders • Blow moulders • Rotational moulders • PE film extruders • Sheet extruders • Cable extruders • Pipe extruders • Profile extruders • Tube and hose extruders • Compounders and masterbatch producers

6th edition

AMI’s Directory

PLASTICS PROCESSORS IN POLAND LOCATION & PRODUCTION DETAILS OF PLASTICS PROCESSING PLANTS

Click here for more details

For more information contact us on sales@amiplastics.com or Tel: +44 (0) 117 9249442

www.ami-publishing.com


Ancillaries |

2013 preview

Ancillaries are the supporting cast of the plastics industry, and the forthcoming K2013 will see plenty of new offerings to choose from. Lou Reade reports

Added advantages Conair’s

The term ‘ancillaries’ has to cover a lot of ground,

integral air manifolds, ducting and wiring on a sturdy

encompassing control, dosing, measuring, drying,

platform for simplified shipping, installation and

blending and a host of other operations that support the

operation. Each hopper can be equipped with a Drying

gravimetric

act of melting and extruding polymers.

Monitor probe that incorporates RTD sensors along its

batch dosing

At K2013, the sheer range of ancillary suppliers will

length. The probe measures the temperature at up to

be breathtaking. As with prime machinery, large

six different points in the bed of plastic material so that

companies dominate the ancillaries market. But nestled

a temperature profile can be created to verify that

between the big stands, there will be many smaller

conditions for proper drying are maintained.

suppliers of ancillary equipment. Once of the biggest players is US-based Conair, and

Up to 15 hoppers equipped with Conair temperature controls can be linked to the DC-T for monitoring and

it will be showcasing a multitude of products across its

duplicate control. All settings can be made, viewed and

range. Its new DC-T TouchView control, for example,

adjusted at the dryer. Data from individual Drying

provides an easy-to-use interface for monitoring and

Monitor probes, including trending graphs, can also be

controlling the entire polymer drying process. It will

displayed on the DC-T monitor – or elsewhere, thanks

form part of a central-drying cell that includes a W300

to the standard Internet connectivity.

Carousel Plus desiccant dryer and a four-hopper

web-enabled and will be networked together at K2013

monitor.

so that anyone with a computer, tablet or smart phone can connect with the controls and monitor conditions or

graphical touch-screen interface clearly shows

change settings. these remote access options to maximise productivity,”

historical temperature data and includes precise

said Doug Brewster, conveying product manager.

dew-point control.

“Whether they are on the other side of the building or

cal, medical and cleanroom applications

on the other side of the world, production supervisors

multi-hopper central drying cells, such as the Resin-

and managers can change settings, respond to alarms,

Works system, which combines multiple hoppers with

perform troubleshooting and other operations as if they

www.pipeandprofile.com

aimed at pharmaceuti-

“Customers have been telling us that they want

easy adjustment of parameters. It shows current and

The DC-T also provides a gateway for controlling

equipment is

with Internet access and the right password credentials

more out of their drying system. An 8in diagonal everything happening in the drying system and allows

and mixing

Controls on other Conair equipment are also

ResinWorks system equipped with the patented drying A host of features can help plastics processors get

Ultrablend

September 2013 | PIPE & PROFILE EXTRUSION

19


2013 preview | Ancillaries

easier to clean and maintain – and an oversized discharge opening to prevent material bridging. Filterless loaders are designed to handle dusty, problem materials like regrind and free-flowing powders that are 100 microns in diameter and larger. A patented ‘filterless insert’ uses continuous reversal of air to separate incoming material from conveying air without filters or screens. Conair will also exhibit its EP1A-03 air-cooled portable chiller with onboard process fluid pump and tank. A hot gas bypass valve controlled via a PID algorithm enables precise control to within 1°C of setpoint. The unit will be shown with optional alarm horn, automatic water make-up and low-level light and rotary non-fused disconnect switch. At the same time, its NCF-819 super-tangential granulator claims to be 30% smaller than granulators Instron’s

were standing in front of the operator interface on the

with similar capabilities. The cutting chamber configu-

offerings

plant floor.”

ration is ideal for handling lightweight bulky parts, but

include the

also produces clean uniform granulate from small

Ceast MF50 and

Vacuum conveying

parts. Different hopper designs and rotor/knife choices

MF30 melt flow

For central vacuum conveying, the company will exhibit

are available. Four different models feature 8in

testers

its FLX loading control, an entry-level system that has

(203mm) diameter rotors, in widths of 10, 14, 19 and

been expanded to handle up to 128 loaders and 40 vacu-

24in (240, 360, 480 and 600mm), and deliver standard

um conveying pumps. In-plant communications are

maximum throughputs of 150-450lbs (68-205kg).

handled by standard industrial Ethernet wiring, meaning it is easy and inexpensive to install and

Cutting edge

expand. A processor can start with a system to manage

UK-based Gillard will exhibit a new extrusion servo

just eight loaders and two pumps (one primary pump

rotary cutter and servo coiler at K2013. Its Servo-Torq

and one back-up pump), then increase The Metrolink

capacity and capabilities in

Plus extrusion cutter combines a brushless AC servo motor with a digital control system to

material

increments by adding input and

selection

output cards. The system can

are possible, along with precise cut length

include high-level functions like

accuracy. New widescreen touch panels allow

Conair has its

first in/first out (FIFO) and priority

easy operator control of the machine.

own autono-

loading, multi-source/multi-desti-

system from

mous control system, so can be used independently

The cutters are available in three maxi-

nation loading, ratio loading with

mum diameter sizes; 30mm, 40mm &

purge, reverse conveying for regrind

100mm. Matching twin-belt Accra-Feed

recovery and loader fill sensing.

caterpillar infeeder/pullers are provided to

Also networked at the show will

match every machine. Multiple lane configu-

be a TrueBlend TB-250 gravimetric

rations are available to handle up to six

blender, with throughputs as high

separate extrusions.

as 431kg/hr (950lbs/hr). The

Remote wireless support via the Internet

blenders are available with through-

is now standard, and all the machines are

puts up to 5443kg/hr (12,000lbs/hr)

fitted with a 3G antenna for use with a

and are accurate to within 0.5% of

local-rate SIM card.

set point on colorant and additive weights. The four hoppers on the blender will be equipped with access loaders

The servo coiler is a compact twin-head machine. The vertical configuration of the reeling drums reduces the footprint of the machine, to save valuable floor space.

and a filterless loader. Access

The servo traverse allows for fine

loaders and receivers feature an

coiling adjustment.

angled hopper – making them 20

activate the knife blade. Very high cut rates

PIPE & PROFILE EXTRUSION | September 2013

There is also a non-contact sonar speed www.pipeandprofile.com


ADDing

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www.4struktol.com • www.velox.com


2013 preview | Ancillaries

Zeppelin supplies a range of

control system for very low tension winding, which Gillard says is vital to avoid product distortion during the coiling process.

pneumatic conveying systems for plastics, and will present a new concept in bulk material

Rheological tests Instron will show a range of systems for determining the rheological properties of plastics and evaluating the behaviour of materials and components under static and dynamic loads. These include the melt flow testers Ceast MF50 and

handling at

the new MF30 (with manual mass selector), a Ceast

K2013

9050 pendulum impact tester, and Ceasts 9350 drop weight tester. The MF30 and MF50 are part of Instron’s new melt flow tester series. The MF30 is a single-weight system, designed to determine melt mass-flow rate (MFR) and melt volume rate (MVR) in accordance with ISO 1133-1 and -2 Procedures A, B, C, and ASTM D1238. Features include a high-resolution digital encoder and an N/C-controlled weight lifter. The lifter incorporates an integrated load cell for controlled compacting and purging operations,

software controls all functions of the tester both during

which improves repeatability and cuts operation time.

single-weight and multi-weight tests.

The manual mass selector – a new integrated option –

Its Ceast 9350 floor-standing impact system is

simplifies configuration and testing, and ensures

designed to deliver high impact energies from 0.59 to

operator safety.

750J. As the high-end model in the Ceast 9300 line, it

With minimal physical effort, there is no heavy mass

includes time-saving features and supports a variety of

handling required and the configuration of the machine

options – from environmental chambers to extra energy.

always remains the same.

The system can be used to test a variety of specimens

The MF50 is the premiere melt flow tester for

and is suitable for a range of impact applications

Conair’s DC-T

single-weight and multi-weight tests. It is compliant

including tensile impact tests, puncture tests, or tests

TouchView

with the latest international standard requirements for

to Izod and Charpy.

control is an

temperature accuracy and stability. During multi-weight

interface for

tests, the system automatically applies up to five of the

automatic contacting extensometer that can enhance

monitoring and

eight pre-installed test masses, ranging from 0.325 to

the productivity of testing laboratories with features

controlling the

21.6kg, in any desired sequence. During the measure-

including automatic gauge length positioning, adjust-

polymer drying

ment, the temperature profile in the barrel is stable and

able contact force with a reference label and multiple

process

accurate according to ISO 1133-2. The Ceast VisualMelt

knife-edge options to accommodate different materials.

Meanwhile, the AutoX750 is a high-resolution

TrendTracker, a software package for Bluehill Software, accelerates data analysis workflow by allowing rapid search and analysis of test results across multiple samples, tested over time and on various test frames. Results are automatically exported to a robust, scalable database. And the company’s automatic carousel feeding system can reduce the time and effort required for performing standardised tests on tabletop tensile testers from its 5960 Series. An optional digital measuring system is available to capture the thickness of all specimens at several points over the length of the specimen with an accuracy of 1 micron. It then transmits the values through an RS 232 interface to the Blue-

22

PIPE & PROFILE EXTRUSION | September 2013

s

hill 3 materials testing software.

www.pipeandprofile.com


Delivering Value packaging packaging

belling belling

pulling pulling and and cutting cutting

and and much much more more for for pipes pipes

www.sica-italy.com www.sica-italy.com

Please visit our stand at K2013 – Hall 16 Stand A22


2013 preview | Ancillaries

Material conveying

Gillard’s Servo-Torq

Zeppelin Systems is a supplier of pneumatic conveying

Plus extrusion

systems for the plastics industry, as well as building silos.

cutter com-

At K2013, it will present a new concept in bulk

bines a servo

material conveying. With Doppelmayr as a partner, the

motor with a

company has developed a ropeway system that could

digital control

transport materials over far longer distances than is

system to

possible using conventional pneumatic conveying.

activate the

At the same time, it has updated the capacity of its

knife blade

Bolt-Tec system – a silo design that allowed silo sections to be bolted together rather than welded. This allows shipping costs to be cut by up to 30%. Bolt-Tec silo segments are transported in standard containers and assembled on site, which is much less expensive than shipping a complete silo. This is of particular benefit in regions with less developed infrastructure, where conventional silos can be shipped by expensive wide load transport only.

Dosing and mixing

Bolt-Tec silos were limited to sizes up to 500 cubic

Motan will introduce a number of ancillary products at

meters, but Zeppelin has doubled this to 1,000 cubic

K2013, ranging from dosing to control.

metres.

Its Ultrablend gravimetric batch dosing and mixing

Henschel Mixing Technology, a business unit of

equipment is aimed at pharmaceutical, medical and

Zeppelin Systems, has developed the HCE series of

cleanroom applications. IntelliBlend technology helps it

cooling mixers with high efficiency. The Mixer HCE

to deliver high dosing precision and consistency. The

(Horizontal Cooler EFF) is available in sizes ranging

system is also equipped with filterless conveying.

from 1,700 to 6,000 litres. Its efficiency guarantees

Meanwhile, its GraviNet GP control system has been

short mixing and cooling times, and it features a newly

joined by a smaller version, GraviNet GP light, a

designed vessel system, plus a cooled mixing tool with

compact control system for up to two dosing modules. It

large surface area. The HCE series has already been

has been designed in a modular way. The operator

tested in PVC manufacturing. Until now, says the

interface has been retained, but now also includes a

company, producing PVC dry blends required blending

WebPanel with a 12.1in TFT touchscreen. Connection to

and heating the PVC with fillers and additives in a

the GraviNet GP light takes place via Ethernet..

heating mixer, before cooling it in a cooling mixer. Due

Staying with control, the Metrolink material selection

to the cooling capacity required and the time available,

system has its own autonomous control system based

the cooling mixer had to be 2.5 times larger than the

on Motan’s MetroNet MK control system – so can be

heating mixer. Now, much smaller cooling mixers can

used independently for remote controlled and automatic

be used, it says.

material supply. Metrolink is compatible with all system conveyor

At the same time, the company will show its CFH rotary feeder, which enables continuous product feeding

equipment and can be networked with other network

and discharge even when the process vessel is pres-

control systems. A maximum of 15 processing ma-

surised. The material is conveyed while the feeder is

chines with up to 16 different materials can be fed from

sealed from the process. Rotor and housing match

the Metrolink tower.

perfectly to minimise air leakage through gaps. Zeppelin’s

Motan has also extended the availability of its ATTN

rigid rotary feeder has been designed to withstand the

automatic temperature and dew point levelling system

different rotor and housing expansions and distortions

to the entire Luxor A dryer range. ATTN has been

generally caused by high temperatures and pressures.

developed for applications where drying of materials can only take place within a narrow dew point ‘window’.

Click on the links for more information:

The dew point of the process air is constantly regulated

❙ www.conairgroup.com ❙ www.gillardcutting.com ❙ www.instron.com ❙ www.motan-colortronic.com ❙ www.zeppelin.com

and documented to ensure regulation precision within 1°C. Motan says that ATTN helps to reduce the risk of over-drying plastic granules at too low a dew point. 24

PIPE & PROFILE EXTRUSION | September 2013

www.pipeandprofile.com


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AMI’s Guides to THE THERMOPLASTICS PIPE EXTRUSION INDUSTRY IN EUROPE, NORTH AMERICA AND SOUTH AMERICA

Three unique reports give you an essential understanding of the pipe extrusion industry and its key players in the European and American continents. • •

Overview of the thermoplastics pipe market Company information on 1020 production sites manufacturing thermoplastics pipes

AMI’s Guide to The Thermoplastics Pipe Extrusion Industry in Europe 490 sites

Thermoplastics pipe extrusion represents a significant market for polymer materials in Europe and America. However this market is affected by the fortune of the building industry and the investments governments are prepared to make to improve their infrastructures. The trends in polymer usage vary across the regions and are affected by a number of factors. These three different reports will provide you with an inside knowledge of the pipe extrusion industry in these different regions of the world. In each guide and for each region you will find the following information:

AMI’s Report on The Thermoplastics Pipe Extrusion Market in North America 315 sites

• Market data and analysis • Company information Production plants are listed alphabetically with their full addresses, telephone, fax numbers, email and website. • Managerial contacts • Polymers processed • Type and size of pipes manufactured

AMI’s Guide to The Thermoplastics Pipe Extrusion Industry in South America 215 sites

Applied Market Information Ltd.

For more details or to order click on each title or contact Régine Futter on: Tel: + 44 117 924 9442 Fax: + 44 117 989 2128 Email: sales@amiplastics.com

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Pipe inspection | process feature

A new way of inspecting weld joints could see polyethylene pipe being used in a wider range of applications, says Mike Troughton of TWI

Volumetric inspection of welded joints in PE pipe Polyethylene (PE) has been used successfully for

replacing it with a weld of unknown quality does not

natural gas and municipal water distribution pipework

ensure the integrity of the pipeline. Volumetric non-

for many decades. Because it is immune to corrosion,

destructive testing (NDT) will not destroy perfectly good

and highly resistant to fouling, it is being considered as

welds and has the added advantage of reduced waste.

applications such as cooling water intake pipework in

Joining methods

nuclear power stations, which typically transport

There are two main types of joint in PE pipes: butt

organically rich seawater. However, one of the main

fusion (BF) and electrofusion (EF). In BF welding the

reasons why this material has not been introduced to

pipe ends, which have been cut square and flat, are

any great extent for these applications is that the

pushed against a heated metal plate until they melt; the

regulatory bodies require the welded joints to be

plate is then removed and the pipes are pushed

inspected volumetrically – and there is currently no

together and allowed to cool, forming a weld. In EF

commercially available, validated inspection system.

welding, the pipe ends are pushed into either end of an heating wire in the inside. Current is passed through

recording the welding parameters used – together with

the coil, which heats up and melts the inside of the

a visual inspection of the joint – supplemented by the

fitting and the outside of the pipes, producing a weld. Phased array ultrasonic testing (PAUT) has been

short-term test. However, visual inspection can only

used widely in the steel pipeline industry and PAUT

examine the external surface of the pipe weld: it cannot

inspection systems are commercially available from

provide evidence of embedded flaws or a weld with

many companies. However, none of these systems has

incomplete fusion or cold fusion. In addition, cutting a

either the software or hardware to provide volumetric

specimen from a weld for mechanical testing and then

examination of welds in PE pipes. Furthermore, there

www.pipeandprofile.com

the field, under

injection moulded fitting, which contains a coil of

welded joints in PE pipes during installation is by

destructive testing of welds on a sample basis using a

was tested extensively in ‘real’ conditions

a replacement for stainless steel in safety-critical

The current practice for assuring the quality of

The system

September 2013 | PIPE & PROFILE EXTRUSION

27


process feature | Pipe inspection

The system can determine a ‘good’ weld (left) from one that is sandcontaminated (right)

are no sealed PAUT instruments available for rugged

last 20 years. It recently led a European-funded

application in a trench environment and there are no

collaborative project, called TestPEP, to develop a PAUT

manipulators integrated with the specific ultrasound

inspection system specifically for PE pipe welds, over a

transducers that can cope with the highly attenuative

wide range of pipe diameters (90-1000mm).

properties of PE. The main challenges in the ultrasonic inspection of

European project

PE pipes are:

TestPEP involved 17 organisations from seven European

● The velocity of the ultrasound is much lower than that

countries. It was a three-year project, which finished in

for metals, which makes it more difficult to generate

April 2013 and had a total value of €3.5m. Its aim was to

angled beams in the plastic material. Angled ultrasonic

design, manufacture and validate a PAUT system for

beams are generated by refraction from a slower

inspecting pipe-to-pipe and pipe-to-fitting (elbows,

medium and there are few materials that will support

bends, reducers, tees) BF and EF joints in PE pipes. The

velocities lower than plastics.

system had to be site-rugged and simple to operate. In

● The attenuation of ultrasound in plastics is very high

parallel, the significance of flaw size and quantity was

compared with metals, and very frequency dependent.

established in relation to service requirements, which

● The inspection system will need to operate from one

was achieved by the short-term and long-term mechan-

side of the welded joint only, as the other side may be

ical testing of joints containing known flaws, and

an elbow, reducer or flange.

comparison with results for welds containing no flaws.

● In BF welds, the flaws are perpendicular to the

The project developed PAUT techniques and

inspection surface, whereas in EF welds the flaws are

procedures for examining BF and EF welds over a wide

parallel to the inspection surface but beneath the coil of

range of pipe sizes. New PAUT probes, probe wedges

heating wire.

and a scanning system were specified, designed and

● The inspections may need to be carried out in harsh

manufactured. In addition, a new lightweight, compact

environments, such as a muddy trench.

and robust ultrasonic instrument was designed and

TWI has been carrying out research on the ultrasonic inspection of both BF and EF joints in PE pipes for the

produced. This device has a large internal memory for data storage, is battery operated and Wifi compatible. Algorithms and software were also developed for

Project partners

analysing the inspection data collected from EF joints.

The project consortium consists of the European Federation for Welding,

sentences the joint based on a comparison between the

Joining and Cutting (EWF), Asociacion Española de Ensayos No Destruc-

measured flaw size and the acceptance criteria.

tivos (AEND), Surface Mount and Related Technologies (SMART Group),

The software generates a map of the weld, estimates the size of any flaws in the weld and automatically

The complete NDT system – including instrument,

Pipeline Industries Guild, Associazione Italiana Prove non Distruttive

probes and scanning system – has been assessed in a

(AIPnD), Vermon, M2M, Plasflow, Isotest Engineering, E.ON Ruhrgas,

number of laboratory and field trials to evaluate its

British Energy, Hessel Ingenieurtechnik, Kaunas University of Technol-

sensitivity, reproducibility and ease of use. The results

ogy, Consorzio Catania Ricerche and TWI.

showed that all the key flaw types highlighted by the

28

PIPE & PROFILE EXTRUSION | September 2013

www.pipeandprofile.com


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to predict the future is to invent it


process feature | Pipe inspection

Rotherham, UK in November 2012. Butt fusion joints in 450 and 630mm PE pipes that had been made for a power station installation were inspected in the factory. In one of the welds, an indication was found at a circumferential position of 240° and a through-wall depth of 20.9mm. The estimated size of the flaw was 5-6mm in the circumferential direction and 2-3mm in the radial direction. This weld was cut out and rewelded. In addition, an indication from an axially misaligned weld was found, due to the step between the internal surfaces of the pipes. Blind trials on EF joints in 110mm PE pipes containing various simulated flaws, including aluminium foil, sand and talc were carried out at EO.N Ruhrgas in Essen, Germany in March 2013. The inspections successfully detected these flaws and distinguished between flawed and unflawed welds. The final trials were carried out in the field in March Trials at

European plastics pipes industry (planar lack of fusion,

2013. The objective was to assess the operation of the

UK-based

fine and coarse particulate contamination, cold welds

system in real environments (a trench). The first trial

Plasflow

and pipe under-penetration in EF joints) can be found.

was the inspection of EF welds in a 710mm PE pipeline

included

at a hydroelectric power station in Bethesda, North

inspection of

Pipe trials

Wales; the second trial was at a gas pipe installation in

butt fusion

Trials were carried out at Radius Systems in Alfreton,

Sheffield, UK, where BF joints in 355mm PE pipe and EF

joints

UK in October 2012. EF joints in 250 and 450mm PE

joints in 250mm pipe were inspected. In both cases the

pipes – which had been in service in Belfast, Northern

prototype system operated perfectly.

Ireland – were inspected in the factory. The results were

Commercialisation of the TestPEP inspection system

compared with X-ray radiographs of sections cut from

is being discussed by the manufacturing companies and

the joints and with mechanical tests. Good correlation

industry associations in the consortium. In the mean-

between the ultrasonic inspection results, the X-ray

time, TWI is offering a worldwide service for the on-site

radiographs and the mechanical test results were

PAUT inspection of welded joints in PE pipes.

obtained.

● Mike Troughton is technology manager for plastics at TWI (www.twi.co.uk)

Further trials were carried out at Plasflow in

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Medical tubing | materials feature

While medical tubing is getting ever smaller, the need for accuracy during production is increasing. Lou Reade reports

With medical technology getting ever more precise, it’s no surprise that this precision extends to the most fundamental of medical products: tubing. Where once medical tubing was only used to deliver

Taking the tube

blood or fluids into the body intravenously, the wide range of medical devices means that ever-smaller tubing is required. American Kuhne has developed a new line of modular

“Medical extruders have told us that their key to

Plastics has

Bessemer, Conair’s sales manager for medical

extended its

micro extruders that are used for this very purpose.

extrusion. “This equipment gives them control of their

The extruders are available in 12, 16 and 19mm

process – so that they can make higher-quality tubing

barrel and screw sizes and are suitable for medical

– as well as set-up and operation features to make their

device and pharmaceutical applications. Output

process more efficient.”

volumes down to 125g/hr can be achieved using standard size pellet shapes and granules. “Micro extruders allow for a short residence time in

meet the needs of medical tubing manufacturers. Available in five models, the tanks can be used to make any size or configuration of tubing, from multi-lumen

tion,” said Steve Maxson, vice president of extrusion

microbore heart and brain catheters to large-gauge

systems. “This protects the molecular weight of the

medical tubing.

end product.” At the MD&M West show, the company ran a Pebax

devices up to 1in (25.4mm) in diameter

Advanced servo-drive and control technology is used tapered and ‘bump’ tubing. The servo-drive technology periodically adjusts the outside and inside diameters

extruder with servo drive and pressure control.

(OD and ID) to expand the tube to create a wider-diame-

inline measuring, monitoring and control systems, and

custom Peek extrusions for

in the Medline puller/cutter to facilitate production of

6333 micro tubing system on a 12mm modular micro It teamed up with Zumbach Electronics, a supplier of

range of

medical

MedVac flood-cooling tanks have been designed to

the barrel, which helps to minimise thermal degrada-

material and ultimately the physical properties of the

Putnam

success lies in controlling process variables,” said Bob

ter bump at a point where a catheter would be attached to other medical equipment.

ancillaries supplier Conair on the demonstration. The microbore tubing made in the demonstration is

Tube expansion

used in precision products like heart and brain catheters.

Meanwhile, US-based Putnam Plastics has built a new

Conair says that its downstream extrusion equip-

manufacturing site to expand production of its range of

ment, such as the MedVac vacuum sizing/cooling tank and Medline puller/cutter, can help to reduce wall thickness and ovality variation. www.pipeandprofile.com

medical tubing. The 92,000 sq ft (8500 sq m) facility in Dayville, Connecticut will allow for expansion of extrusion September 2013 | PIPE & PROFILE EXTRUSION

33


materials feature | Medical tubing

technology development and manufacturing operations. It will include dedicated space for Putnam’s three key

custom Peek extrusions for medical devices. Its latest offering – large diameter, thin wall tubing

growth initiatives: clean manufacturing, product

for endoscopy and laparoscopy – extends its range from

finishing and technology development.

microcatheter size up to 1in (25.4mm) in diameter.

This includes a new 6,000 sq ft (560 sq m) ISO Class

The single lumen Peek extrusions include vascular

8 cleanroom for extruding and finishing components

catheters with diameters as small as 0.01in (0.254mm)

that require greater regulatory controls. Finishing

and wall thicknesses of 0.002in (0.050mm). Larger

operations will include printing, insert moulding,

extrusions for non-vascular applications, such as

tipping, welding and assembly for finished tube

Natural Orifice Transluminal Endoscopy Surgery (Notes)

components used in medical devices.

devices, are available in diameters up to 1in (25.4mm)

“Our existing space will continue to provide tradi-

with 0.01in (0.254mm) wall thicknesses. Thin-wall Peek

tional extrusion services,” said Jim Dandeneau,

tubing can be manufactured semi-transparent or in

Putnam’s chief executive officer. “The expansion allows

custom colours. Putnam also offers plasma enhanced

us to support increased demand for more complex,

printing on it.

comprehensive extrusion components and will serve as

“Processing temperatures for Peek are much higher

a showcase for emerging extrusion technologies

than traditional catheter materials such as urethanes

available for medical devices.”

and polyamides,” said Larry Alpert, new product

Putnam’s new technology developments include

development manager at Putnam. “Few companies

continuous manufacturing technologies that minimise

have the temperature capabilities or controls to extrude

manual operations to produce complex, composite

Peek and those that do often focus on either small

catheter designs.

diameter tubes or large, solid shapes. Larger tubes

The company has already extended its range of

provide new possibilities for emerging medical devices.” Peek has become well established in the medical industry due to its biocompatibility. Its flexural modulus of 595,000 psi (4,102MPa), which is nearly 10% higher than polyimide, provides high pushability and buckling

The Medline puller/cutter, and other

resistance for thin wall tubes. Peek is also melt processible and can be extruded in large diameter, thin wall tubes.

Conair downstream

Anti-microbial performance

extrusion

Plastics Color Corporation (PCC) has released a

equipment, can

research paper on antimicrobials in polymers. It

help extruders

provides a brief history of antimicrobial agents in

of medical tubing reduce wall thickness

general and explains their development and usage in medical and other applications. It examines the application of antimicrobial plastic

and ovality

resins as a response to demands for plastic products that

variation

inhibit microbial growth. In the US, it says, 1.8m hospitalassociated infections lead to 99,000 deaths each year. The paper, available by request on the company’s website, provides an in-depth look at the chemical and biological methods used to inhibit microbe growth, the spread of disease and the deterioration of materials. “Using select antimicrobial formulations matched to appropriate resins, the plastics industry is producing a wide variety of antimicrobial polymers for use in medical, industrial, commercial, marine and home applications,” says the paper. An example is seen in a recent collaborative project. NEU Specialty Engineered Materials, a subsidiary of PolyOne, is to develop antimicrobial formulations for small-diameter catheters and medical tubing with

34

PIPE & PROFILE EXTRUSION | September 2013

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materials feature | Medical tubing

The CRD 600 automatic fitting inserter provides

Microspec Corporation. The partnership will rely on PolyOne’s Withstand antimicrobial technologies. “NEU’s experience in engineered materials,

high-speed

combined with PolyOne’s antimicrobial technologies

insertion of

and Microspec’s capabilities, provide a solid technical

tapered-barb

solution for catheter and medical tubing OEMs,” said

fittings into medical tubing made from

Matthew Borowiec, commercial director of PolyOne Engineered Materials in North America. Small-diameter catheters are increasingly

Medalist

used for paediatric applications and to promote

medical

patient comfort. Microspec has produced tubing

elastomers

with an outside diameter as small as 0.004in (0.1mm) and multi-lumen tubing as small as 0.12in (0.305mm). It can also layer antimicrobial additives in the outer portion of multi-lumen tubing, which can help keep costs down and places the antimicrobial on the surface and outer band of the device where it is needed.

Replacing PVC

And Lubrizol launched two ranges of thermoplastic

An automatic fitting inserter from Clean Room Devices

polyurethane (TPU) at the recent MD&M East confer-

can help medical product manufacturers obtain the

ence in the US.

advantages of Teknor Apex Medalist elastomers over

Firstly, it introduced eight new medical-grade

PVC, while increasing productivity in the assembly of

aromatic TPUs, to extend its Pellethane line of prod-

tubing and connectors.

ucts. The new additions are a mix of polyester and

“Tapered-barb connectors fit into the Medalist TPE tubing with a retention strength that exceeds the level specified by most global OEMs for infusion systems and

polyether aromatic TPU products that offer a wide range of properties for use in the medical industry. They included grades with stiffness and non-kinking

is greater than levels achieved with either adhesive or

properties for multifunctional medical device applica-

solvent bonding,” said Richard Faulkner, medical

tions such as tubing and catheters.

market manager for the TPE division of Teknor Apex. The CRD 600 unit cycles at a rate of 2,300 per hour

At the same time, it introduced a flame-retardant TPU that is suitable for medical applications. Lubrizol says it is

and, with the addition of a feeder bowl, enables an

the first product of its kind to feature high flame proper-

operator to make 1,800 insertions per hour, including

ties, low halogen content and a soft, matte or gloss finish.

time for handling the tubing and inspecting the results. “Because it allows for insertion of over-sized barbs

In medical applications, a material’s Limiting Oxygen Index (LOI) is a critical component. With an LOI of 30,

into tubing with a smaller internal diameter, it ensures

the new TPU exhibits low smoke and low toxicity,

a stronger fit than solvent bonding,” said Ronald Del

enhancing its suitability for an array of applications,

Valle, president of Clean Room Devices. “Our system

including medical cabling.

eliminates the presence of solvent chemicals and odours in the cleanroom.” Medalist MD-500 elastomers are in commercial use as

“This flame-retardant TPU will be useful in many medical applications,” said Ralf Hüther, global business manager of Lubrizol LifeScience Polymers.

alternatives to PVC in tubing applications. The compounds exhibit comparable crystal clarity and mechanical

Click on the links for more information:

properties, provide similar clamp resilience and resis-

❙ www.americankuhne.com ❙ www.zumbach.com ❙ www.conairgroup.com ❙ www.putnamplastics.com ❙ www.plasticscolor.com ❙ www.neuinc.com ❙ www.polyone.com ❙ www.teknorapex.com. ❙ www.lubrizol.com

tance to kinking and necking, have a similar ‘feel’ and are much more flexible and less dense than PVC. They also undergo minimal colour shift upon heat ageing after sterilisation by gamma irradiation. A typical compound in the series, Medalist MD-575, exhibits 70% less heat-aged colour shift than a gamma-stabilised PVC compound of comparable hardness, says Teknor. 36

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Pipe dies | machinery feature

Improving the energy efficiency of pipe dies and pipe heads can bring significant savings to the extrusion process. Lou Reade reports

In the round It’s hardly surprising that pipe dies and pipe heads play a vital role in the efficiency of the production process – as every ounce of extruded material has to pass through them in the transformation from raw material to finished product. Tecnomatic of Italy has completed its Venus series of pipe heads, so that the range now covers diameters from 5 to 2600mm. The series features a new flow channel at its heart, which has been designed to take account of the raw materials PE100 CR and PP-H. The series was defined by its diameter range, so it was possible to make approximations according to the law of models. This resulted in the same behaviour in levels of pressurisa-

larger internal surface is regulated with heating/cooling

tion and distribution of the melt for all the pipe heads,

blocks in the distributor area or in the ranges of fit and

says Teconomatic. This had led to a 40% increase in

mandrels. Cooling with water offers the advantage of a

output, compared to die heads with outdated diameter

greater cooling capacity where the system operates

ranges or comparable heads from other manufacturers.

with temperatures lower than 100°C.

While the distributors have a smaller diameter

Overall, says Teconomatic, the heads are smaller,

compared to the maximum possible pipe size, the lower

shorter and lighter for every diameter range. The

pressurisation level of the moulds is considerable. A

heating power is also reduced. Insulation can reduce

new feeding system of the single spiral channels

heat loss by radiaation, as well as uneven temperature

contributes to reduced pressure, which can reduced

distribution, which helps to save on heating energy and

energy consumption by around 10%, says the company.

energy costs during both heating and processing.

The new die lengths have been cut by 50%, have a

diameter pipe heads. It developed the Venus 2000 and

external diameters, says the company. In a diameter

Venus 3000 for high performance extrusion. The

range lower than 1000mm, processing is done with a

concept is based on two extruders with an ejection force

compounding procedure, then with a heading procedure

of at least a tonne of the same dimensions, with ejection

for larger dimensions.

adjustment. The extruders are synchronised and pipe increases line productivity and ensures fast pipe

Identical die sets can be used for the Multi 2 and Multi 3

turnaround times and increased production capacity.

Tecnomatic based on multiple spiral distributors. In the larger Venus heads, the temperature of the www.pipeandprofile.com

changing, is seen here fitted with multilayer pipe head and IPC technology

production is adjusted according to weight/metre. This

end rings define the necessary opening of the dies. series, another new series of co-extrusion heads from

for fast dimension

Tecnomatic offers another innovation with its large

lower volume and are designed to produce three

The mandrels consist of two parts, and the small

The QuickSwitch system,

At the same time, all Venus models allow internal pipe cooling. The basic head, range of fit and mandrels allow the pipe to be insulated up to the head, in order to September 2013 | PIPE & PROFILE EXTRUSION

39


machinery feature | Pipe dies

Tecnomatic has extended its range of Venus die heads

aspirate air inside it. This results in several product

range) and QuickSwitch systems can be equipped with

advantages, including: improved distribution of the

cost-saving internal pipe cooling (IPC) technology. This

internal stress due to even cooling of sides; reduced

gives manufacturers a competitive edge because the

contraction at the extremity of the pipe after cutting;

efficient cooling system better cost efficiency. In addition

lower thermal stress of the internal surface; and high

to external cooling, the pipe is also cooled from the inside

OIT values that lead to longer lasting pipes.

using ambient air, which is suctioned with the help of a side channel compressor against the extrusion direction.

Die heads at K KraussMaffei Berstorff will highlight a number of its pipe

As well as reducing space and investment costs, it reduces cooling water consumption.

die technologies at the forthcoming K2013 exhibition. Firstly, it has extended its QuickSwitch concept – a pipe die head that allows rapid adjustment of pipe size

Theysohn, the Austrian extrusion specialist, will also

– to the 250-450mm diameter range.

launch a number of new machines at K2013, in addition

The company says that the proven system guarantees economical use of energy and materials during the dimension change. KraussMaffei

PVC output

“Our unique system is now also successful when

to several pipe heads and dies. One system will produce three-layer PVC pipe with a foam or recycled core. The TW 4-10 Feedblock and the PVC pipe head RKS 3 for pipe dimensions 75-250mm

Berstorff’s

used with pipes with a larger diameter, of 250-450mm,”

foamcore or recycling core pipe offers high flexibility with

single-screw

said Peter Roos, president of the company’s extrusion

a wide dimension range. The latest generation of the

extruder will

technology segment. “The enormous advantages carry

feedblock allows an optimum on-skin wall thickness

be seen at

weight here as the retrofitting is significantly more

distribution and high weight reduction. With the new

K2013 running

complex for larger diameters. With our QuickSwitch

feedblock many different formulations and PVC-K-values

with a five-

system we fully satisfy our claim to offer the customer a

can be processed on one system. With the change of the

layer pipe head

system with maximum availability.”

pipe head – and no other changes in the feed block

5L RKW 31-40

Polyolefin extrusion systems (in the 110-2500mm

system – both smaller and larger pipe dimensions (32-710mm) can be produced very simply, says Theysohn. At the same time, the DS 20 diverter block with 508mm axial distance allows the installation of two RKS PVC pipe heads for the production of pipes from 32 to 110mm OD. This installation is used for hot water pipes from C-PVC as well as pressure, sewage and conduit PVC pipes with outputs up to 1300kg/h. Output performance can be doubled in comparison with a single strand line and the space requirement can be reduced by about 50%. The use of bigger extruders reduces the energy consumption by about 17%, compared with two single extrusion lines, says the company. Click on the links for more information:

❙ www.tecnomaticsrl.net ❙ www.kraussmaffei.com ❙ www.theysohn.at 40

PIPE & PROFILE EXTRUSION | September 2013

www.pipeandprofile.com


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Pressure pipe | process feature

Taking the strain Alternative piping materials are often used to add extra performance to pipes. So, rather than relying only only PE100, for example, many high strength pipes are made from composite materials of some kind. Composite Fluid Transfer has won a JEC Innovation Award for its composite pressure pipe, which uses Celstran continuous fibre-reinforced thermoplastic composites (CFR-TP) from Ticona.

Pressure pipes come in many different forms – from oriented PVC to fibre-reinforced composites. Lou Reade reports

The award, in the ‘Pipes & Water Management’ category, recognises the Fiberflex-11 pipe with multiple

only 128lbs (58kg), while the same length of 12in HDPE

Ticona’s

options for robust connections that US-based Compos-

SDR 9 pipe weighs 655lbs (297kg), making the compos-

Celstran is

ite Fluid Transfer designed for general water transport

ite pipe 80% lighter. The Fiberflex-11 pipe system also

commonly used

infrastructure applications.

offers several coupling/connector options, including a

to make high

The pipe incorporates Celstran CFR-TP continuous fibreglass reinforced high-density polyethylene (HDPE)

two-bolt patent-pending quick coupling design.

thermoplastic composite tape, which is wound around a

diameter pipe rated at a 250lbs/sq in operating

specially designed, extruded thin-wall HDPE thermo-

pressure) is designed for general water transport

plastic liner and heat treated in a proprietary process

infrastructure, including distribution systems, oil and

developed by Composite Fluid Transfer. The pipe

gas operations, hydraulic fracturing feed water and

construction adds an outside layer of HDPE film

produced water, large irrigation systems, tank farm

manufactured by Valéron Strength Films to protect the

operations and dewatering systems.

system from both ultraviolet and abrasion damage. At 4.26lbs/ft, the Fiberflex-11 pipe is lighter than

It can be altered to operate at higher pressures, in tougher environments, at higher temperatures, with

comparable diameter and pressure rated composite and

larger diameters, and with any type of piping system

plastic pipe, says Ticona. Two people can easily lift and

connections. Burst pressure of the finished pipe can be

carry the pipe, which avoids the cost of unloading

increased from the current design, which is rated at

equipment, increases safety and minimises work site

500 pounds per square inch (psi), by varying the

damage and reclamation costs. A 30-foot section weighs

number of layers of Celstran CFR-TP tape on the

www.pipeandprofile.com

strength pipes

Fiberflex-11 pipe (10.5in inner diameter, 11.1in outer

September 2013 | PIPE & PROFILE EXTRUSION

43


process feature | Pressure pipe

The researchers tested a standard polyethylene (PE) pipe, and two types of composite pipe: one (commercialised at SMX) had an inner layer of cross linked PE (PEX), a middle layer of aluminium and an outer layer of PE; the second (called PEO2) comprised inner and outer layers of PE, and a middle layer of ethyl vinyl alcohol (EVOH). Dumbbell and strip-shaped specimens were cut out from each type of pipe, along the longitudinal direction. Ring-shaped specimens were also prepared. By conducting tensile tests and tensile creep tests at the elevated temperature, mechanical properties – due to differences of the longitudinal and circumferential directions of a pipe – were examined. Molecor will present the

Results of the tensile creep tests were compared

thin-wall HDPE pipe liner. Ticona will showcase the pipe at the forthcoming

with those of stress rupture tests at the elevated

latest develop-

Society of Petroleum Engineers’ technical conference

temperature. The effectiveness of the ring-shaped

ments in PVC-O

and exhibition in New Orleans, and at JEC Americas

tensile creep test was also investigated.

technology at

2013 on 2-4 October in Boston, USA. The three develop-

next month’s

ment partners will receive their award during JEC

ties – due to differences of the stress in longitudinal and

K2013

Americas 2013.

circumferential direction – were not seen in either the

exhibition

For the tensile test, changes in mechanical proper-

PE or SMX pipes.

Passing the test

In the study, every specimen for the tensile creep

Meanwhile, Japanese researchers have assessed a new

test had broken at the inside of the ring, so the

test method for composite pipes, which could deter-

researchers tried to simulate the deformation of test

mine long term performance much more quickly.

pipe at the tensile creep test using FEM analysis of a PE

The stress rupture test at elevated temperatures is the usual way to evaluate long-term performance. The creep

ring specimen. This agreed with the actual test results. “It means that some parameters should be con-

fracture of pipes is generated by the applied internal

trolled in order to prevent inside of the ring from

pressure. But there are some disadvantages, including

breaking,” said the researchers.

long testing times and the need for large equipment. The researchers, from Advanced Fibro-Science at the Kyoto Institute of Technology, have evaluated a new creep testing method – the ring tensile creep test – for composite pipes such as multilayer pipes. The results agree with the stress rupture test and FEM simulation analysis.

Click on the links for more information:

❙ www.ticona.com ❙ www.compositefluidtransfer.com ❙ www.valeron.com ❙ www.kit.ac.jp ❙ www.molecor.com

PVC orientation boosts pipe strength Molecor of Spain will present the latest

while Molecor Tech develops the

for 630mm pipe at 25 bar, and is now

developments in oriented PVC (PVC-O)

technology to manufacture PVC-O pipes

ready to launch 800mm pipe.

technology during next month’s K2013

up to DN 800mm (30in) and 25 bar (365

exhibition, including details of its

psi).

Integrated Seal System (ISS+) and PVC-O

Molecor made its first PVC-O pipe, a

This year the company moved to a larger facility in order to increase manufacturing capacity and improve its

DN200mm, in 2007. This was extended to

R&D operation. Its patent pending

DN400mm in 2008, which was then the

Integrated Seal System (ISS+) allows the

molecular orientation technology applied

‘unofficial’ limit for PVC-O pipe. In 2010, it

manufacture of socketed PVC-O pipes

to pipelines for water transport. It has

began to make pipes of 450 and 500mm

with automated integration of the gasket,

two lines of business: Molecor Canaliza-

diameter – which was exhibited at K2010.

retaining the orientation degree in critical

pipes up to DN 800mm (30in). The company is a pioneer in air-based

ciones makes and sells PVC-O pipes,

44

Since then, it has added the capacity

PIPE & PROFILE EXTRUSION | September 2013

areas of the pipe.

www.pipeandprofile.com


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Materials | technology

medical compounds

Foster adds new compounds for catheters Foster Corporation has launched ProPell thermoplastic polyurethane (TPU) and polyether block amide (PEBA)

enhances the surface of

Foster’s new ProPell compounds reduce tackiness and friction in catheters

parts without substantially altering the physical properties of the polymer.

compounds for the improved

Tests show that parts

manufacturing and handling of

produced from ProPell TPU

medical catheters. The

have a dry coefficient of

company says that these new

friction of 0.05, representing

compounds dramatically

a 66% reduction compared to

reduce tackiness and friction

the unmodified TPU polymer

in soft and flexible polymers

with a hardness of 80 Shore

while maintaining other

A. The results are even more

physical properties of the

flexibility to navigate vascular

to each other. Catheters made

pronounced in PEBA

unmodified polymers.

pathways without causing

from these materials can also

polymers with a hardness of

trauma. However, the inherent

be difficult for physicians to

35 Shore D.  Parts made from

PEBA polymers, with hardness

Soft grades of TPU and

high friction and tackiness of

handle and push through

ProPell PEBA have dry

properties ranging from 80

these polymers can cause

vascular pathways.

coefficient of frictions 84%

Shore A to 35 Shore D, are

handling problems during

commonly used in medical

catheter tube extrusion and

compounds use a proprietary,

polymer.

catheters that require

packaging since the parts stick

non-migratory additive that

❙ www.fostercomp.com

ProPell low-friction

lower than the unmodified

PVC compounds

coupling agents

Addivant commercialises renewable compatibilisers

Axiall adds bio-based compounds

Addivant, the former

compatibilisers in formula-

rice husks, flax, hemp and

antioxidant and UV stabiliser

tions where high renewable

others. Its new Polybond

Axiall, the merger of Georgia

business of Chemtura, has

content raw materials are

polymer modifiers can be

Gulf and PPG’s commodity

commercialised its first

desired.

used to increase the mechan-

chemicals business, has

ical and physical properties of

launched its Aspire flexible

polymer modifiers derived

The company says that

from renewable resources.

there is an increased focus on

such composites by improv-

PVC compounds which

Polybond 6009 and 6029 act

reinforcing biopolymers with

ing the chemical coupling of

feature bio-based plasticis-

as coupling agents or

natural fibres, such as wood,

the polar and non-polar

ers. They meet the USDA’s

components.

BioPreferred Program target

The compatibilisers can improve adhesion between bioplastics and natural fibres, such as rice husks

www.pipeandprofile.com 

Polybond 6009 and 6029 do not use petroleum-based

with more than 25% renewable content.

feedstocks and they both

Aspire phthalate-free,

contain greater than 95%

bio-based vinyl compounds

renewable content raw

are claimed to offer improved

materials. Addivant says that

performance at a price that is

the coupling agents can also

equal to traditional flexible

be used as a tie layer in

PVC formulations. The

multi-layer extruded

compounds use organic

applications where a high

stabilisers and have low VOC

renewable content is desired.

emissions.

❙ www.addivant.com

❙ www.axiall.com

September 2013 | PIPE & PROFILE EXTRUSION

47


technology | Machinery

welding

Extrusion welders for plastic pipe Ritmo of Italy has developed

thanks to special shoes and

the Stargun R-SB range of

continuously rotating 45° and

extrusion welders, which can

90° adapters.

be used on a range of plastic

The R-SB 20 and R-SB 30

products.

models are very compact,

All models are light,

while the R-SB 40 is a more

compact and smooth during

powerful unit, with three

the welding phase. The whole

different handgrips. The

line is supported by a series of

R-SB 50 is designed for more

interchangeable Teflon shoes

demanding jobs, and can be

that allow it to adapt to many

supplied with a special

kinds of welding situation.

handgrip for geomembrane

The technology is particu-

welding.

larly designed for the welding

The R-SB 60 is a hydraulic

of plastic sheets and pipes,

to a 6kg/h model at the top of

setting and reading the

unit with high extrusion

including corrugated pipe.

the range. All extruders have a

working temperature, rotating

capacity. Its gearcase can be

compact blower, dual control

lateral handgrip, power

powered with an electric

models, with different

of the temperature (both

regulator and safety power cut

generator, or with a gasoline

outputs. It starts with a

blower and extruder), wide

off system. The extruders can

or diesel unit.

2.2kg/h model, and goes up

multifunction display for

also be used in tight spaces,

❙ www.ritmo.it

The series consists of five

pipe extrusion

Extruder and pipe head boost PVC pipe production in Brazil Krona Tubos e Conexões, a

most modern in South

Brazilian manufacturer of pipe

America and we are proud

and pipe fittings has ordered

that it will be operating two

an extruder/pipe head

new models of extruder and

combination from KraussMaf-

pipe head,” said Bruno

fei Berstorff.

Sommer, manager of the

The 36D KMD 108-36 E2/R

extrusion division at the

twin-screw extruder and

Krauss Maffei do Brasil

KM-RK 23XL pipe head will be

subsidiary.

used at the company’s plant in

The KMD 108 E2/R rounds

Joinville to produce PVC

off the product range of

sewage pipes in the dimension

KraussMaffei Berstorff 36D

screw extruders are designed

fluidic aspects in order to

range from 75 x 1.8 to 250 x

twin-screw extruders for

for processing a range of PVC

ensure high pipe quality. They

7.3mm.

medium output rates. It is

formulations. The HPG (high

work according to the

designed for the range from

performance geometry) screw

mandrel holder principle

has been a customer of

450 to 1000kg/h. The KM-RK

concept give high process

which is ideal for processing

KraussMaffei Berstorff for

23-250 pipe head can be used

engineering flexibility,

thermally sensitive materi-

several years and has decided

with an output rate of up to

ensuring careful and homoge-

als. Accurate melt distribu-

to extend to new models.

1000kg/h.

neous material processing.

tion helps to minimise wall

Krona Tubos e Conexões

“The Joinville production plant is regarded as one of the 48

In combination with the pipe heads, the 36D twin-

PIPE & PROFILE EXTRUSION | September 2013

Pipe heads are designed

thickness variation.

according to thermal and

❙ www.kraussmaffei.com www.pipeandprofile.com


WIND TURBINE

BLADE MANUFACTURE

2013

International conference and exhibition on wind blade composites design, manufacturing and markets CLICK HERE FOR DETAILS

HEADLINE SPONSOR

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Download the programmes for these forthcoming conferences Simply click on the brochure cover or link to download a PDF of the full publication

Polyolefin Additives PolyolefinAdditives2013 International conference on compounding of polyolefins focusing on PP and PE materials and applications

10-12 September 2013 Hotel Nikko, Düsseldorf, Germany * + 19% German VAT

Images courtesy of: songwon International aG

speCIal OFFeR: Save €100* if you register before 19th July 2013 Organised by: Applied Market Information Ltd.

Media supporters:

Sponsored by:

The sixth Polyolefin Additives conference is being organised by AMI in Düsseldorf, Germany on 10-12 September. The programme covers the latest developments in a variety of additives for improving the properties, durability and appearance of PE and PP.

➤ Click here to download

1 1534 or email to: ge@amiplastics.com

11 1534 or email: kl@amiplastics.com

Plastics in Photovoltaics

Medical Grade Polymers Medical Grade Polymers 2013 Technical conference debating material selection, safety and manufacturing of medical devices

Photo courtesy of HTP-Meds, LLC.

PLASTICS IN PHOTOVOLTAICS 2 0 1 3

International conference on backsheets, encapsulants and other polymer materials in photovoltaic systems

September 10-11, 2013 Hilton Philadelphia City Avenue, Philadelphia, Pennsylvania, USA

Images courtesy of: EVONIK INDUSTRIES AG and SBM SOLAR INC.

SPECIAL OFFER: Save $200 if you register before August 2, 2013 Media supporters:

Organized by: Applied Market Information LLC

➤ Click here to download

Fire resistance in Plastics

AMI’s next conference on Medical Grade Polymers takes place in Woburn/ Boston, Massachusetts, USA, on 17-18 September. Download the brochure, which has the full programme with its impressive selection of expert speakers.

FIRE RESISTANCE IN PLASTICS 2013 Trends and technical developments in the international flame retardant industry

September 17-18, 2013 Images courtesy of: HTP-MEDS LLC and POLYONE CORPORATION

Crowne Plaza Boston/Woburn, Woburn, Massachusetts, USA

12-14 November 2013

AMI is running the eighth international Fire Resistance in Plastics conference on 12-14 November in Cologne, Germany. The high-level programme covers the latest technology developments, market trends and regulatory changes.

Maritim Hotel, Cologne, Germany

SPECIAL OFFER: Save $200 if you register before August 9, 2013 Organized by: Applied Market Information LLC

AMI’s third North American conference on Plastics in Photovoltaics is taking place on 10-11 September 2013 in Philadelphia, PA, USA. Download the programme which covers the latest market and technology trends in solar power.

Media supporter:

➤ Click here to download

Images courtesy of: chemische fabrik Budenheim KG and international antimony association

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Special offer: Save €210* if you register before 4th October 2013 Organised by: Applied Market Information Ltd.

Media supporter:

Sponsored by:

➤ Click here to download

fax back to: +44 (0) 117 311 1534 or email: ab@amiplastics.com

Compounding World Forum

Polymer Foam POLYMER F O A M 2013 International conference on blowing agents and foaming technology for polymer materials

AMI is holding the Polymer Foam 2013 conference in Hamburg, Germany, on 19-21 November. Download this brochure to see the line-up of speakers who will cover developments in blowing agents and foaming technology for polymers.

The international conference on business strategies and new technologies for compounders

19-21 November 2013

December 10-11, 2013

Marriott Hotel, Hamburg Germany

Hilton Philadelphia City Avenue, Philadelphia, Pennsylvania, USA * + 19% German VAT

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Images courtesy of: Coperion, Foster Corporation, PolyOne, Renault, and Teknor Apex

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SPECIAL OFFER: Save $200 if you register before November 1, 2013

Media supporters:

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Organized by: Applied Market Information LLC & Compounding World

Sponsored by:

AMI and Compounding World magazine are holding the first Compounding World Forum in Philadelphia on 10-11 December. It will cover technical compounding developments, including market trends, new additive technologies and getting the most from twin-screw extruders.

➤ Click here to download

To see our full line-up of more than 25 plastics industry events over the next 12 months, please visit www.amiconferences.com


This month’s free brochure downloads Simply click on the brochure cover or link to download a PDF of the full publication

Reedy: additives guide This six-page brochure from Reedy International covers the company’s range of polymer additives and masterbatches, including foaming agents, nucleating agents, performance enhancers, processing aids and coating additives.

Starrett Bytewise: profile inspection Laser Measurement

This brochure from Starrett Bytewise features the Profile360 laser measurement system for the in-line inspection of extruded window profiles. It monitors angles, squareness, gaps, grooves and other key dimensions.

OLUTIONS

Profile360 for Extruded Window Profiles Your Measurement Solution for Extruded Window Profiles Starrett-Bytewise... leading the way with in-line profile inspection for door and window lineals, profiles and seals. • •

Monitor angles, squareness, gaps, grooves, and other key dimensions in real-time with on-screen optical comparator and trend graph displays Alarm when dimensions change

View real-time profile geometry from any PC on your network

Report complete dimensional statistics for each run

Inspecting with the Profile360 •

Line Operators can immediately observe and react to manufacturing problems

Production Managers can quickly review historical run data

Quality Control Managers can better understand the process and factors that cause variation

Faster startups, faster product development, faster die design

• •

Improve customer satisfaction Reduce inspection labor and material scrap

Contact Jim Williams - Sales Director, Profile360 jwilliams@starrett.com +1-404-915-7516

w w w .re e d yi n tl . c o m

➤ Click here to download

Sica: downstream equipment This brochure from Sica covers the company’s wide range of downstream equipment for plastic pipe production. It includes haul-off devices, saws, cutting systems and belling machines.

➤ Click here to download

Piovan: refrigeration systems This 12-page brochure from Piovan focuses on the company’s refrigeration systems, including scrollcompressor chillers, screw-compressor chillers, inverter-driven chillers, thermo-refrigerators and free-cooling systems.

➤ Click here to download

Bulletin No. 2502

PDF

10/12

Specifications subject to change.

➤ Click here to download

706-323-5142

Unicor: pipe corrugation R

the corrugator experts

Innovations Solutions Quality Service

Machinery Brochure

This updated 52-page brochure from Unicor covers the design, production, applications and advantages of corrugated pipes. Plus it has details on the firm’s wide range of pipe corrugation systems.

➤ Click here to download

Tecnomatic: extrusion die heads This 24-page brochure from Tecnomatic provides detailed information on the company’s wide range of extrusion die heads. These include the latest Venus designs for PE/PP processing and its RadialType Distributor for PVC pipes.

➤ Click here to download

If you would like your brochure to be included on this page, please contact Claire Bishop. claire@amimagazines.com. Tel: +44 (0)20 8686 8139


extruder of the month

Reschcor Head office: Date founded: President:

Elkhart, Indiana, USA 1982 Tom Reschly

Employees:

Around 80

Ownership:

Private

Profile:

Reschcor, which until recently was Omega Plastics, specialises in making a range of extrusion profiles up to 24in wide. At the same time, it produces both rigid and flexible tubing, with outside diameters of 0.15in to 8in. The company can also handle wood plastic composites, multi-hollow extrusion and both co- and tri-extrusion.

Plant location:

At its 65,000 sq ft factory in Elkhart, the company has 16 extrusion lines. Here, it makes a wide range of extruded pipes and profiles, including products for the agricultural, building, fencing, railing, medical, refrigeration and garden markets. Materials used range from rigid, flexible and cellular PVC to WPCs, HIPS, polyolefins and TPEs.

Recent projects:

The company was recently commissioned to design and develop a co-extruded profile that required it to bond cellular foam PVC to flexible PVC. The two materials could not be combined in the usual way of a co-extrusion: the flexible PVC had to be applied downstream, which meant moving the co-extruder down the line and making a second die – through which the main profile ran. Later, the customer decided that a material change was needed: the foam was replaced with rigid PVC, and a new die was designed to run a part with very heavy and small areas.

To be considered for ‘Extruder of the Month’, contact the editor on lou@pipeandprofile.com

Forthcoming features The next issues of Pipe and Profile Extrusion magazine will have special reports on the following topics:

October Extruder technology Downstream equipment Trenchless pipe installation K2013 show issue

November/December Materials handling equipment Wood-plastic composites technology Cross-linked polyethylene K2013 review issue

Editorial submissions should be sent to Lou Reade: lou@pipeandprofile.com For information on advertising in these issues, please contact Claire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139


Catch up on our recent issues for FREE Simply click on the cover to see the full magazine, or download the issue in the relevant Apple or Android app Pipe and Profile – July/August This issue of Pipe and Profile Extrusion examines the latest developments in recycling technology, window profiles, testing procedures for pipes, and control and instrumentation systems. It also has useful links to prepare for your visit to K 2013 ➤ Click here to view

Compounding World – August The August edition of Compounding World has special features on the latest developments in PVC plasticizers and functional fillers, plus the big debate about the pros and cons of oxo-degradable additives. ➤ Click here to view

Film and Sheet – July/August The July/August edition of Film and Sheet Extrusion has special reports on the optimisation of foam formulations, market trends for rigid film and sheet, developments in downstream equipment, and the latest designs for blown film dies. Plus there’s a useful guide to visiting K 2013. ➤ Click here to view

Pipe and Profile – May/June The May/June edition of Pipe and Profile Extrusion takes a close look at wood plastics composites, examines options for simulating plastic pipe extrusion, and explores the latest innovations in profile dies. It also reviews PVC additive developments. ➤ Click here to view

Compounding World – July Compounding World’s July issue has a special focus on colour, looking at how colour works and how it can be monitored. Plus there are features on antimicrobial additives, thermoplastics elastomers and melt filtration systems. ➤ Click here to view

Injection World – July/Aug The July/August edition of Injection World has special features on: durable applications for bioplastics; the latest automation systems; optimising hot runners; developments in clarified PP; and getting ready for K 2013. ➤ Click here to view

Take out your own FREE subscriptions to any of the magazines. Click on the logos below to simply register on-line.


dates for your diary

Global exhibition guide 2013 3-6 September 5-7 September 10-12 September 25-26 September 4-6 October 16-23 October 19-22 November 20-23 November 5-8 December 12-16 December 2014 21-23 January 28-31 January 29 Jan - 1 Feb 11-13 February 16-19 February 4-6 March 7-10 April 16-22 June

Applas, Shanghai, China Plasti & Pack, Lahore, Pakistan Plastec Midwest, Chicago, USA Mediplas, Birmingham, UK PPP Africa, Nairobi, Kenya K 2013, Düsseldorf, Germany Yiwu Packaging, Printing & Plastics, China Plastics & Rubber Indonesia, Jakarta Plast Eurasia, Istanbul, Turkey Plastivision, Mumbai, India

www.applas.com www.pk-plastipack.com www.plastecmidwest.com www.mediplasuk.com www.pppexpo.expogr.com www.k-online.de www.yiwuppp.com www.pamerindo.com www.plasteurasia.com www.plastivision.org

Swiss Plastics, Lucerne, Switzerland Interplastica, Moscow, Russia Samuplast, Pordenone, Italy Plastec West, Anaheim, CA, USA Saudi Plastics & Petrochem, Riyadh Plastics & Rubber Vietnam, Ho Chi Minh Plastivision Arabia, Sharjah, UAE Argenplas, Buenos Aires, Argentina

www.swissplastics.ch www.interplastica.de www.samuplast.it www.plastecwest.com www.saudipp.com www.plasticsvietnam.com www.plastivision.ae www.argenplas.com.ar

AMI conferences for pipe & profile extruders 10-12 September 2013

Polyolefin Additives, Düsseldorf, Germany

17-18 September 2013

Medical Grade Polymers, Boston/Woburn, USA

12-14 November 2013

Fire Resistance in Plastics, Cologne, Germany

10-11 December 2013

Compounding World Forum, Pennsylvania, USA

24-26 February 2014

Pipeline Coating, Vienna, Austria

24-26 February 2014

PVC Formulation, Duesseldorf, Germany

11-13 March 2014

Cables, Cologne, Germany

18-20 March 2014

Masterbatch Asia, Bangkok, Thailand

20-22 May 2014

For information on all these events and other conferences on film, sheet, pipe and packaging applications, see

www.amiplastics.com

Pipes in Infrastructure, Duesseldorf, Germany

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www.pipeandprofile.com And don’t forget to tell your colleagues, customers and suppliers about the magazine. You can use the e-mail button above (the envelope symbol in the browser) to help spread the word.


Pipe & Profile September2013