75~250 PVC-U PIPE PRODUCTION LINE
PVC pipe extrusion line is a complete production system used to manufacture PVC (polyvinyl chloride) pipes of various diameters and applications, such as plumbing, irrigation, electrical conduits, and sewage systems. The process involves melting PVC resin, shaping it through an extruder, cooling, and cutting it into desired lengths.
- Pipe application: PVC-U pipe
- Material: PVC, calcium carbonate, lead stabilizer, stearic acid etc
- Production pipe range: 75~250 MM
- Production capacity: 650KG/
- Main extruder: SJZ92/188 conical twin-screw extruder, AC 110 KW
- Total installation power: 200KW
- Line central height: 1100MM
- Speed controlled by ABB inverter
- SIEMENS12 “LCD display screen
1. PVC Raw Material Loader
Purpose: To store, blend, and deliver a consistent mixture of raw materials to the extruder.
Key Components:
- Storage Hoppers: Large containers holding the main PVC resin and additives (heat stabilizers, lubricants, impact modifiers, pigments, fillers).
2. SJZ 92/188 Conical Twin-screw Extruder
Purpose: To plasticize (melt) the PVC dry blend into a homogeneous molten state and pump it forward under high pressure.
Key Components:
- Barrel: Hardened steel cylinder with heater bands and cooling fans to maintain precise temperature zones.
- Screw: Specially designed for PVC; conveys, compresses, shears, and melts material.
- Drive Motor: Provides torque to rotate the screw at controlled speed (RPM).
- Feed Throat: Opening where the PVC blend enters the barrel.
- Control System: Monitors and controls temperature, screw speed, and melt pressure.
3. Extrusion Die & Pipe Head
Purpose: To form the molten PVC into a continuous tubular shape with desired diameters.
How it works:
- Mandrel (Pin): Forms the pipe’s inner diameter.
- Die: Forms the pipe’s outer diameter.
- Design: Ensures uniform wall thickness and balanced material flow.
4. ZDT250-2K-6M Vacuum Calibration Tank
Purpose: To calibrate the pipe’s outer diameter and begin cooling.
How it works: The pipe enters a sealed tank with cooling water. Vacuum pressure pulls the pipe wall against calibrator sleeves for exact diameter.
5. PL250-1K-6M Cooling Tank
Purpose: To further cool the pipe until fully solidified and dimensionally stable.
Key Features: Long water bath or spray tunnel with controlled temperature for gradual cooling, preventing stress and warping.
6. QY250 Haul-off (Puller) Unit
Purpose: To pull the pipe steadily through tanks at constant speed.
How it works: Caterpillar-style tracks with rubber pads grip the pipe. Speed is synchronized with extruder to maintain wall thickness.
7. QG250 Planetary Cutting Machine
Purpose: To cut the moving pipe into precise lengths.
Types:
- Planetary Cutter: Rotating blades give clean, chip-free cuts on large diameters; ideal for critical applications.
8. DF250-9M Stacking & Packaging System
Purpose: To automatically offload, stack, or package finished pipes. Gently receives and organizes pipes after cutting.
Raw material+additive → Screw Loader → Screw Feeder → Twin-screw Conical extruder → Extrusion die → Vacuum calibration tank → Cooling tank → Haul-off machine → Cutting machine → Stacker
PVC-U (Unplasticized Polyvinyl Chloride) pipes, also known as rigid PVC pipes, are one of the most widely used piping materials in the world for a variety of applications. Their benefits stem from the fact that no plasticizers are added to the compound, making it rigid and strong.
Here are the key benefits of PVC-U pipes:
1. Exceptional Corrosion Resistance
Description: Unlike metal pipes (iron, steel, copper), PVC-U is completely inert and does not rust, rot, or corrode from exposure to water, aggressive soils, and a wide range of chemicals. This is its single biggest advantage over metallic alternatives.
Benefit: Dramatically longer lifespan (often 50+ years), minimal maintenance, and consistent water quality without rust contamination.
2. High Mechanical Strength and Durability
Description: PVC-U has high hoop strength (resistance to internal pressure), making it excellent for pressure applications like potable water mains. It is also very resistant to mechanical shock and abrasion during handling and installation.
Benefit: Reliable performance under pressure, reduced damage during transport and installation, and high resistance to soil movements and loads.
3. Lightweight and Easy to Handle
Description: PVC-U pipes are about 1/5th the weight of concrete and 1/6th the weight of similar-sized cast iron pipes.
Benefit: Much easier and safer to transport, handle, and install. This reduces labor costs, eliminates the need for heavy lifting machinery on site, and speeds up installation time significantly.
4. Excellent Hydraulic Characteristics
Description: The internal bore of PVC-U pipes is extremely smooth, resulting in a very low Hazen-Williams roughness coefficient (C=150). This smoothness minimizes friction loss (head loss).
Benefit: Allows for the use of smaller diameter pipes compared to rougher materials to achieve the same flow rate, leading to material savings. It also resists scale and biofilm buildup, maintaining flow efficiency over its entire lifespan.
5. Cost-Effectiveness
Description: PVC-U is typically the most economical piping option both in terms of material cost and installation cost. The lightweight nature reduces transportation and labor expenses, and the ease of joining saves time.
Benefit: Lower total project costs, making it the preferred choice for municipal and large-scale projects with tight budgets.
6. Easy and Secure Joining Methods
Description: The primary method for joining PVC-U pipes is with solvent cement welding. This process chemically fuses the pipe and fitting together into a single, monolithic piece, creating a joint that is often stronger than the pipe itself.
Benefit: Creates leak-free systems without the need for expensive, skilled labor like welders or threaders. Other methods like rubber ring joints also allow for quick push-together installation.
7. Chemical Resistance
Description: PVC-U is highly resistant to a wide range of chemicals, including acids, bases, salts, and alcohols. This makes it suitable not just for water, but also for industrial and chemical effluent applications.
Benefit: Versatility for use in various industrial and laboratory settings where corrosion would destroy metal pipes.
