Benefits of using BorSafe™ HE3490-IM to produce Injection Moulded Fittings

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BorSafe™ HE3490-IM solves problems and reduces costs for fitting manufacturers

BorSafeHE3490-IMisthefirsttailormadePE100materialspecificallydesignedforinjectionmoulding

pipefittings.Experiencehadshownthatitwasdifficulttoproducegoodqualityinjectionmoulded

fittingsathighproductivitylevelsusingstandardPE100extrusionmaterialandtheproblemsgotworse

asthesizeofthefittingsincreased.

BorSafeHE3490-IMwasdevelopedusingadvancedpolymerizationtechnologyandahexene

comonomerandthematerialcombinesthestrengthofaPE100materialwithdramaticallyimproved

flowcharacteristics.Theresultisthatgoodlookingfittingscanbeproducedwithareducedscraprate

andwithincreasedproductivity(lowerunitcosts).Examplesofsomeoftheimprovementsthatfitting

manufacturershavebeenabletoachieveareshownintheoppositepictures.

BorSafeHE3490-IMhasenabledfittingmanufacturerstoenhancetheirfittingproductmixwithnew

productdevelopments.Forexample,therearesuccessfuldevelopmentsofsophisticatedelectro-

fusion(EF)fittingsupto315mmtoservicethegrowingPE100gaspipemarketinsomeregions.The

newEFfittingspassedthestringentqualificationtestingforgasproducts,thankstoBorSafeHE3490-IM

whichprovidegoodqualityandprocessabilitytoproducefittingsofstableandaccuratedimensioning.

Anotherexampleisthesuccessfuldevelopmentofheavywallstubflangeswithoutvoidsorwarpage.

Easier processing of BorSafe HE3490-IM means reduced costs, due to:

• Lowertemperatureinjection –lessheatingenergy

• Lowerinternalstressesandwarpage –lowerscraprates

• Improvedreproducibilityofdetail –improvedquality–lowerscrap

• Shortercoolingtime/Reducedcycletime –lowerunitcost

• Increasedproductivity –lowerstocks –greaterflexibility

• Greatlyimprovedappearanceoffittings –improvedsaleability

Typical Fitting Cost Structure

Fixed Cost

Material Cost

Process Cost

Savings in Costs

IndiaImproved fitting appearance SangirPlasticssawmajorimprovementstothesurfaceoftheirspigotfittingsrangewhentheyusedBorSafeHE3490-IMmaterial.

SushilMandhanasaidofthetrials“BorSafe HE3490-IM is a very good material for injection moulding, producing a uniform finish with no flow marks observed on the products, also the shrinkage is quite low compared to other PE100 materials.”

BorSafe HE3490-IM helps fitting producers solve problems around the world

United KingdomReduced scrap rate

TheimprovedreplicationofBorSafeHE3490-IMonsmallfittingswasalsodemonstratedonFusion’srangeoftappingsaddles.

Thisfittingcontainsaninternalhousingforanemergencyflowstopvalvewhichisactivatedifthehouseconnectionbreaksandrapidlyreleasesgas.Oftenfittingswererejectedduetopoorseatingofthevalveandbrittlenessofthespigot–untiltheyusedBorSafeHE3490-IM.

ChinaReduced overall cycle timeIntrialsatZiboJielininShandong,Chinaona160mmelectrofusioncouplertheywereabletoreducetheinjectiontemperatureby10to15°C.Thisenabledthemtoreducetheoverallproductioncycletimefrom420to390secondsandthesurfaceappearanceofthefittingswasmuchimprovedandtheovalityreducedfrom1.0mmto0.6mm.

CommentingafterwardsonthetrialsLuGuangjiong,ChiefEngineerofZiboJielinsaid:“Clearly the improved flow properties of the Borouge PE100 injection moulding material have a very positive influence on both the quality and the productivity of the fitting tested.”

IndiaImproved dimensional control Sprinklerirrigationcouplersneedtobetoughandhaveanaccurateexternalprofiletomatchthemetalquickreleasemechanismbecausetheyareregularlymovedaroundtheteaestates.

IndiansystemmanufacturersRamaPlastics,NimbusIndustriesandHallMarkAquaallcarriedouttrialswithBorsafeHE3490-IMandfoundmarkedimprovementsinthequalityandthedimensionalaccuracyofthefittingswhichmakesthemmoreattractiveandeasiertouse.

Some useful web sites and references Borouge www.borouge.com

Borealis www.borealisgroup.com

PE100+Association www.pe100plus.net

TheGulfPlasticsPipeAcademy www.gulfplasticspipe.org

WaterandSanitationfortheUrbanPoor(WSUP) www.wsup.com

WaterfortheWorld www.waterfortheworld.net

“InnovativePE100materialimprovesthequalityand McGoldrick,J.etal,PlasticPipesXIII, productivityofinjectionmouldedfittings” Washington,2006

“Developmentofawholelifecostingmodelforlarge Shepherd,M.etal.PlasticPipesXIII, diameterwatermains” Washington,2006

“DevelopmentofaNewHighPerformancePEpressure Kania,G. pipesystem,fromdesignphasetoreality”. NoDig.Rome2007

“SpecialhighqualityPE100pipematerialsensurelong McGoldrick,Jetal. servicelifeandsolvepracticalend-userproblems”. WiesbadenerKunststoffrohrtage,2007

“TheUseofHighStressCrackResistantPEPipesfor Walton,D.&Murali,M. DemandingInstallationConditions” SAPPMAConference,2008.

AtoughinitiationforPE100inKuwait’soilindustry Hayes,P.,PlasticPipesXV,Vancouver,2010

Borouge PE 100 Grades

BorSafe HE3490-IMThisisaPE100compoundwithimprovedflowproperties,whichmakesitidealfortheproductionofinjectionmouldedfittings.Thehigherflowenablesalowermelttemperaturetobeusedwhichreducesbuiltinstresses(lowerscraprate)andtheproductioncycletime(lowercosts).

BorSafe HE3490-LSThisisaPE100pressurepipecompoundprovidinganexcellentbalanceofproductionandenduseproperties.Itisahighoutputmaterialwhichhasexceptionallowsagpropertiesbutcanbeusedequallywellinsmallersizes,whichmeansyouonlyneedonematerialinthesilo.

Borsafe HE3490-LS-HThisPE100pressurepipecompoundhasexceptionalresistancetostresscrackingmakingthepipelessvulnerabletofailureduetoinstallationdamage.Idealfortheouterlayerofamultilayerpipeinstalledusingdirectionaldrillingorpipeburstingtechniques.

Commercial Reference Material Type Colour Application

BorSafe HE3490-IM PE100Highflow Black Injectionmouldedfittings BorSafe HE3490-LS PE100LowSag Black Extrusionofpipes-allsizes BorSafe HE3490-LS-H PE100HSCR Black Highstresscrackresistantforpipesfor demandinginstallationconditions

About Borouge

Borougeisaleadingproviderofinnovative,valuecreatingplasticssolutions.Ajointventurebetween

theAbuDhabiNationalOilCompany(ADNOC),oneoftheworld’smajoroilandgascompanies,and

AustriabasedBorealis,aleadingproviderofchemicalandinnovativeplasticssolutions,Borougeisa

groundbreakinginternationalpartnershipattheforefrontofthenextgenerationofplasticsinnovation.

BorougehasitsheadquartersintheUnitedArabEmiratesandSingapore,employsapproximately

1,600peoplerepresentingmorethan40nationalitiesandservescustomersinmorethan50countries

acrosstheMiddleEast,Asia-Pacific,Indiansub-continentandAfrica.BuildingonBorealis’unique

Borstar®technologyandexperienceinpolyolefinsformorethan50years,Borougeprovides

innovative,valuecreatingplasticssolutionsfortheinfrastructure(pipesystems,andpowerand

communicationcables),automotiveandadvancedpackagingmarkets.

In2010BorougetripleditsannualproductioncapacityinAbuDhabito2milliontonnesandan

additional2.5milliontonnesperyearwillbeintroducedbymid-2014tocreatetheworld’slargest

integratedpolyolefinsplant.BorougeisalsoinvestinginplantsandlogisticshubsinAsiaandan

InnovationCentreinAbuDhabi.TodayBorougeandBorealishaveamanufacturingcapacityofover

5.4milliontonnesofpolyethyleneandpolypropyleneannually.FocusedonValueCreationthrough

Innovationtheyensurethattheircustomersthroughoutthevaluechain,aroundtheworld,canalways

relyonsuperiorproductsandsecurityofsupply.

BorougeiscommittedtotheprinciplesofResponsibleCare®andtogetherwithBorealisproactively

contributestowardsaddressingtheworld’swaterandsanitationchallengesthroughtheirWaterfor

theWorld™initiative.

Visitwww.borouge.comandseehowweareShapingtheFuturewithPlastics.

DisclaimerTheinformationcontainedhereinistoourknowledgeaccurateandreliableasofthedateofpublication.Borougeextendsnowarrantiesandmakesnorepresentationsastotheaccuracyorcompleteness of the information contained herein, and assumes no responsibility regarding theconsequencesofitsuseorforanyprintingerrors.Ourproductsareintendedforsaletoindustrialand commercial customers. It is the customer’s responsibility to inspect and test our products inordertosatisfyhimselfastothesuitabilityoftheproductsforthecustomer’sparticularpurpose.Thecustomerisalsoresponsiblefortheappropriate,safeandlegaluse,processingandhandlingofourproducts.Nothinghereinshallconstituteanywarranty(expressorimplied,ofmerchantability,fitnessforaparticularpurpose,compliancewithperformanceindicators,conformitytosamplesormodels,non-infringementorotherwise),norisprotectionfromanylaworpatenttobeinferred.Nostatement

hereinshallbeconstruedasanendorsementofanyproductorprocess.NooneisauthorisedtomakerepresentationsorgivewarrantiesorassumeanyotherliabilitiesonbehalfofBorougeexceptifinwritingandsignedbyadulyauthorisedBorougeemployee.InsofarasproductssuppliedbyBorougeareusedinconjunctionwiththirdpartymaterials,itistheresponsibilityofthecustomertoobtainallnecessaryinformationrelatingtothethirdpartymaterialsandensurethatBorougeproductswhenused together with these materials are suitable for the customer’s particular purpose. No liabilitycanbeacceptedinrespectoftheuseofBorougeproductsinconjunctionwithothermaterials.Theinformationcontainedhereinrelatesexclusivelytoourproductswhennotusedinconjunctionwithanythirdpartymaterials.

For more information contact: info@borouge.comorvisitwww.borouge.com

BorECOandBorsafearetrademarksofBorealisgroup.BorstarisaregisteredtrademarkofBorealisgroup.

SALES & MARKETING Singapore (Head Office) Borouge Pte Ltd 1GeorgeStreet#18-01Singapore049145Tel:+6562754100Fax:+6563771233Email:info@borouge.com

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