helix pipe dies - battenfeld.se · coat 800 vsi o.d. (350 x 0.5 to 800 x 7.0) mm 800 kg/h kryos...

PO pipe dies to suit a wide range of applications

helix pipe dies

With its helix series, battenfeld-cincinnati offers its customers an extensive choice of custom-made PO pipe die models which can be adapted to meet a great variety of demands. If, for example, a wide range of different materials are to be processed with high throughput rates, the 2-step distribution con-cept of VSI dies is the answer. By contrast, side-fed distributors or spider-type mandrel dies are the ideal equipment for processing materials such as EVOH or PEX-b, where dwell time is a critical factor.

The custom-made dies include models such as modifi ed VSI dies for 4-layer applications, 7-layer dies with 4 color stripes to produce PP pipes with fi berglass and an oxygen barrier layer, but also multi-layer dies to process materials sensitive to dwell time, such as PEX-b. Complex multi-layer dies can be equipped with different distribution concepts for the individual layers according to the special requirements in each case.

Dies made to fi t a great variety of customers’ needs

Our offer:

Optimal melt distribution concepts are available to suit all areas of application and specifi cation profi les (VSI, spiral mandrel distributors, side-fed distributors, spider-type mandrel dies or simple, compact radial distributors)

Your advantages:

High throughput Precise wall thickness distribution Long service life through short dwell time of the

melt in the die

Applications for pipe dies

Single-strand and twin-strand pipe extrusion

PE 63, PE 80, PE 100 for pressurized pipes with color stripes for gas and water transport

Many different telecommunication pipes Waste water pipes for non-pressurized applications PP for hot water pipes PP-R pressurized pipes for the chemical industry PP-H drainage or sewage pipes, smooth or with fi ller content Pipes made of ABS, PEX, LDPE, LLDPE, PVDF, PPO, ABS/PC or

PA Cable conduit pipes for power supply cables made of PP-O or

other pure polymers

Large-diameter pipe extrusion (up to 2,500 mm)

PE 100 for pressurized water pipes PE 80 or PE 100 non-pressurized drainage or sewage pipes in

wastewater treatment plants

Co-extrusion

Heating pipes with oxygen barrier layers Smooth telecommunication pipes with silicone layer;

corrugated telecommunication pipes with/without silicone layer PP sewage pipes with brown outer layers, white inner layers

and foamed middle layers, middle layers with fi ller content or made of reclaim materials

Sewage pipes made of black PE with a white inner layer PE pipes with a scratch-resistant protective outer layer, a fl ame-

retardant outer layer or a removable protective layer PC or PC/ABS cable conduit pipes with an electro conductive

outer layer for electromagnetic shielding of data cables PE pipes with a gasoline-resistant inner layer made of PA Pipes made of different types of PE 100

Coated pipes

Composite pipes (e.g. aluminum-coated) Steel pipes (adhesive layer or outer layer) Corrugated pipes (third outer layer) Other pipes (telecommunications, special underwater pipes)

The unique VSI dies from battenfeld-cincinnati come with a 2-step distributor con-cept consisting of a spiral mandrel for preliminary distribution and a lattice basket distributor for detail distribution. Particularly outstanding attributes are the excellent homogenization, the wide processing window and the consistent, reliable product quality for all pipe dimensions. VSI dies yield high output rates with relatively small dimensions and are thus particularly well adapted to meeting numerous process tech-nology requirements.

VSI multi-layer dies are extremely maintenance-friendly thanks to their separate distri-bution systems for each layer, since the individual systems can be cleaned and serviced separately. In co-extrusion processes, the inner and outer layers are united with the middle layer as late as possible, so that several different materials, and in some cases also different temperatures, can be used, as the distributors are not positioned on top of each other, but staggered.

Their modular design makes it possible to set the dies either for three-layer applications or for color stripes, and to adapt them to special customer specifi cations as well.

VSI mono- and multi-layer dies

3

3-layer pipe with a brightly colored inner layer for inspection purposes

PE pipe for fuel lines with an inner layer made of polyamide

VSI-T – the VSI die with an EAC (Effi cient Air Cooling) tempering system

With EAC, battenfeld-cincinnati has set new benchmarks in pipe extrusion. With an air current fl owing against the extrusion direction, the pipe is now also cooled from the inside. This raises extrusion performance.EAC can be used for PE and PP pipes with diameters ranging from 63 to 2,500 mm in diameter and wall thicknesses of up to 150 mm. An existing VSI die can be converted quickly and at low cost into a VSI-T, by replacement and/or modifi cation of just a few components. This is possible for all VSI mono-layer and most VSI multi-layer dies (helix 250 VSI or higher). The proven VSI system with excellent melt distribution and homogenization and short dwell times is preserved. Easy assembly and disassembly also remain unchanged.

Schematic depictions:

Central melt delivery Decentral melt delivery

PE pipe for fuel lines with an inner layer made of polyamide

With the EAC system, the length of the cooling section can be shortened by at least 30% for pipe diameters of up to 500 mm, depending on the application, and by at least 40% for pipe diameters above 500 mm. Alternatively, the throughput of the pipe extrusion line can be increased accordingly. The energy of the heated exhaust air from internal pipe cooling can be reclaimed for purposes such as pre-heating granulates. The system also allows individual tempering via the pipe’s circumference. This is achieved through segments placed around the circumference of the die.

With the help of a melt cooling device precisely positioned between the spiral mandrel and lattice basket distributor elements, the melt temperature can be lowered gently and extremely evenly. The main cooling medium is the ambient air, which, similar to internal pipe cooling, is sucked in through the melt cooling device in the die. The technical design of VSI-T+ offers the following advantages:

Reduction of sagging in thick-walled pipes with high output rates Reduction of pipe ovality Further shortening of the required cooling section All advantages offered by the high-performance, 2-step melt distribution concept of the VSI die. The modular

design with its retrofitting options remains unchanged. Melt color change times are the same as for standard VSI dies The active intensive melt cooling system can be operated independently of internal pipe cooling The use of ambient air as the cooling medium minimizes operating costs and maintenance expenses The contamination-free exhaust air discharged from the melt cooling device can be used unfiltered for granu-

late pre-heating or room heating The internal pipe cooling and active intensive melt cooling systems can use the same exhaust air ventilator,

which reduces capital investment

Schematic depiction of a helix 630 VSI-T+ with central melt delivery

Schematic fl ow simulator depiction of the VSI-T+ active intensive melt cooling system

VSI-T+ – the VSI pipe die with active intensive melt cooling

KryoS – effi ciency newly defi ned

KryoSys is a system which offers extreme effi ciency and top performance in pipe extrusi-on. It can be used for all PE and PP mono-layer pipes with diameters ranging from 110 to 1,200 mm. Through air cooling of the inner pipe surface and additional melt cooling inside the die, it is possible to reduce the energy consumption and shorten the cooling section by 40 to 50%. The KryoS concept offers decisive advantages in processing materials prone to sagging. Even for large wall thicknesses (in relation to the pipe diameter to be produced), the KryoS distribution concept has defi nite advantages due to its highly effective cooling performance.

The KryoSys system also promotes better quality in the end product. Thanks to the intensive cooling process, the drop in the OIT value is kept relatively small, and the temperature distribution in the pipe wall is more even. The lower melt temperature at the die outlet leads to reduced sagging. This is particularly important for high wall thicknesses. Thanks to the integrated die outlet and mandrel heating system, a smooth, glossy surface can be achieved in spite of the lower melt temperature. KryoS pipe die

Coating dies

battenfeld-cincinnati also offers modular coating dies which can be adapted to a wide range of applications. Side-fed distributors are used for smaller pipes with thin walls. VSI technology is used for pipes from 220 mm upwards. The latter is particularly recommended for large throughputs and large wall thicknesses. VSI technology operates with mode-rate pressures of, say, 250 bar and ensures low melt temperatures even at high throughput rates.

The advantages of battenfeld-cincinnati multi-layer coating dies are the modular design of every single layer and consequently optimized fl ow geometries in every case. For the outer layer (e.g. PEX-b) and the inner layer (e.g. adhesive layer; EVOH; adhesive layer), double side-fed distributors can be used. Elaborate centering of the individual layers can be dispensed with thanks to the optimized distribution of the melt across the circumference.

Depiction of a coat 700-2 VSI die for steel pipe coating (maxi-mum throughput rate > 3,000 kg/h)Schematic depiction of a coat 40 side-fed die

Schematic depiction: helix 63-5 VSI withcompression unit for the adhesive layer

Schematic depiction: helix 1000-5 VSI5-layer die

Our custom-built VSI multi-layer dies can be combined with either spiral mandrel or side-fed distributors according to the customer’s choice. Depending on the materials to be processed, the optimal distribution concept is used in each case.

This yields the following advantages:

Top-quality distribution of the functional layers across the circumference Mechanically and thermally homogeneous melt distribution

Minimal dwell time range for materials which start a process of cross-linking or thermal degradation following melting (e.g. PEX-b and EVOH)

Long service life for the dies Minimal expense for servicing and cleaning of the critical flow surfaces thanks to strategi-

cally positioned parting lines, without dismantling of the other components

Fiberglass-reinforced PP-R pipes with a layer thickness distribution of 25-50-25

5-layer pipe with oxygen barrier layer

Special VSI multi-layer dies

helix PO pipe dies - output rates and technical data

Coating dies

Pipe die Outer diameter Warranty output*

coat 40 P O.D. (8 x 0.2 to 40 x 2.0) mm 125 kg/h



coat 220 VSI O.D. (75 x 0.5 to 220 x 7.0) mm 650 kg/h





KryoS pipe dies

Pipe die Outer diameter Warranty output*

helix 25-250 KryoS O.D. (110 to 250) mm 1,200 kg/h



helix 63-1200 KryoS O.D. (350 to 1,200) mm 2,500 kg/h

* All output rates quoted are based on the battenfeld-cincinnati material reference list for polyethylene. Output rates may vary, depending on materials processed as well as upstream and down-stream equipment used.

VSI pipe dies

Pipe die model

Range of applicationWarrantyoutput*

Choice of equipment options

Internal pipe cooling VSI-T

active melt cooling VSI-T+

Co-ex–innerlayer

(5 to 15) %

Co-ex–outerlayer

(5 to 15) %Color stripes

centraldelivery

decentraldelivery

helix 20 VSI O.D. (4 x 0.5 to 20 x 4.0) mm max. 300 kg/h – – – X XX X



helix 125 VSI O.D. (25 x 1.8 to 125 x 17.1) mm max. 600 kg/h O O O X XX X

helix 160 VSI O.D. (32 x 1.8 to 160 x 26.6) mm max. 700 kg/h O O O X X X

helix 250 VSI O.D. (50 x 1.8 to 250 x 34.2) mm max. 1,200 kg/h O X X X X X



helix 630 VSI O.D. (160 x 6.2 to 630 x 57.2) mm max. 2,000 kg/h X – X X X X

helix 800 VSI O.D. (250 x 4.9 to 800 x 58.8) mm max. 2,000 kg/h X – X X X X

helix 1000 VSI O.D. (250 x 4.9 to 1,000 x 59.3) mm max. 2,000 kg/h X – X X X X

helix 1200 VSI O.D. (280 x 10.7 to 1,200 x 120.0) mm max. 2,000 kg/h X – X X X X

helix 1600 VSI O.D. (630 x 12.3 to 1,600 x 120.0) mm max. 3,000 kg/h X – X O O X

helix 2000 VSI O.D. (630 x 12.3 to 2,000 x 120.0) mm max. 3,000 kg/h X – X – – X

helix 2500 VSI O.D. (1,000 x 24.5 to 2,500 x 120.0) mm max. 3,000 kg/h X – X – – X

– = not included in the supply schedule X = available

O = available as an option XX = available for up to 4 co-ex outer layers

Symbol legend:

helix PO pipe dies - output rates and technical data

battenfeld-cincinnatiGermany GmbH

Königstraße 5332547 Bad Oeynhausen

P +49 (5731) 242-0F +49 (5731) 27124

[email protected]

www.battenfeld-cincinnati.com

battenfeld-cincinnati (Foshan)Extrusion Systems Ltd.

2 Jinxiang Road, Daliang, ShundeFoshan, Guangdong

P +86 (757) 2238 0110F +86 (757) 2221 1801 / 2238 0195

[email protected]

www.battenfeld-cincinnati.com/china

battenfeld-cincinnatiAustria GmbH

Laxenburger Str. 2461230 Wien

P +43 (1) 61006-0F +43 (1) 61006-8

[email protected]

www.battenfeld-cincinnati.com

battenfeld-cincinnatiUSA

823 S. By-Pass, P.O. Box 832McPherson, KS 67460, USA

P +1 620 241-6843F +1 620 241-0207

[email protected]

www.battenfeld-cincinnati.com/usa

Edition 3 / 09-2013

Subject to technical alterations.

helix pipe dies - battenfeld.se · coat 800 vsi o.d. (350 x 0.5 to 800 x 7.0) mm 800 kg/h kryos...

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