Line for PE pipes up to 1,600 mm diameter

A new high-capacity line for the extrusion of polyethylene pipes with a diameter of up to 1,600 mm has been supplied by Tecnomatic to a major European pipe manufacturer. This state-of-the-art line brings together Tecnomatic’s cutting-edge Zeus EVO series gearless extruders and the innovative Venus 1600 die-head, designed to meet the demands of large-diameter, thick-walled pipe production with unparalleled precision and output efficiency.

At the heart of this advanced line are two Zeus EVO series extruders, engineered to deliver outstanding power and efficiency. The updated screw design improves material flow plasticization and reduces energy consumption. The new optimized spiral feeding bush ensures a smooth and consistent material feed, minimizing fluctuations and enhancing homogeneity, a critical factor for producing large-diameter pipes with uniform wall thickness. Together, the extruders deliver a cumulative output of almost 2,000 kg/h, which enables high-speed, essential for the increasingly demanding market requirements in large-diameter pipe production. Each extruder is equipped with a gravimetric dosing system featuring three separate components for ultra-precise dosing and weight control. This gravimetric system ensures that material feed and pipe weight are tightly regulated, allowing for exceptional meter weight accuracy across each run. The precision dosing plays a critical role in maintaining product consistency, particularly vital in producing large-diameter pipes, where wall uniformity is key to meeting quality and performance standards.

The line includes the redesigned Venus 1600 double-spiral die-head, which is central to producing large-diameter pipes with uniform wall thickness. The Venus 1600 is engineered specifically for pipes of this calibre and integrates innovative mechanical and thermal centring solutions, ensuring optimal thickness uniformity even with very high wall dimensions. The double-spiral design of the Venus 1600 promotes even material flow, reducing the risk of thickness inconsistencies often associated with large pipe diameters. The centring system provides a two-fold approach: mechanical adjustments align the die-head for correct positioning, while thermal control ensures temperature stability within the die. This combination allows for precise, on-the-fly adjustments to maintain pipe centring and thickness uniformity under varying production conditions.

Achieving high output for large-diameter pipes requires an exceptional cooling and vacuum system, which Tecnomatic has addressed with a vacuum length of over 20 metres. This extended vacuum zone provides rapid and effective cooling, essential for maintaining pipe shape and structural integrity during high-speed production. The optimized vacuum design helps the line achieve superior production rates without compromising on quality.

The line is complemented by premium downstream equipment. This includes a 12-caterpillar haul-off and a knife cutting unit that work in sync with the line’s output capacity, ensuring smooth and precise handling of pipes throughout the production process. This high-quality downstream setup minimizes the risk of deformation and maintains the pipe’s roundness and clean cutting finish, crucial for large-diameter applications where dimensional accuracy and surface quality are non-negotiable.