Qingdao Kruto Plastic Machinery Co., Ltd. is located in the beautiful seaside city Qingdao, Shandong Province. We specialize in the production of plastic production extruders and auxiliary equipment. With more than 20 years of experience in plastic machinery manufacturing, as well as a serious attitude towards customers and a responsible mentality, we absorb the design concepts of European experts and hundreds of experimental data to produce efficient single-screw extruders.
Why Choose Us
Rich Experience
Our company has been in the plastic extruder industry for more than 20 years. We have accumulated rich experience and continuously optimizes our own technology and equipment.
Broad Market
Our products are not only popular in China but also sold to dozens of countries overseas, and the companies we cooperate with are all over the world.
High Quality Products
Our products will undergo several product inspections before being sent out to ensure product quality. And we have 100% quality assurance responsibility for our customers, and we will be responsible for any quality problems that arise.
Excellent Service
We have online customer service every day to answer your questions about the product, handling the customer complaint and solve problem for customers. Our customer service will also follow up on product usage.
Jacket pipe extrusion machine is of vital importance in manufacturing, representing a profound intersection of engineering precision and polymer science. The process involves the transformation of polyvinyl chloride (PVC) from its raw state into a versatile and durable material widely used across various industries. This transformation is predominantly facilitated by extruder machines and specialized equipment designed to melt, shape, and mold PVC into pipes of varying diameters and thicknesses. The sophistication of these machines, combined with advancements in extrusion technology, has significantly enlarged of PVC pipe applications, extending its utility from simple plumbing solutions to complex infrastructure projects.
Composition of Jacket Pipe Extrusion Machine
Extruder
The extruder is the core equipment of the entire line and is responsible for heating and melting the plastic raw material and extruding it through the die head into the desired shape of pipe. The extruder usually consists of a screw, a heating zone, a cooling zone, a motor and a control system. The screw is responsible for heating and pushing the plastic pellets to melt and form a uniform molten material.
Die Head
The die head is the component that moulds the molten plastic material into a specific cross-sectional shape. Its design and construction determine the shape and size of the final pipe. The die head usually consists of multiple extrusion holes through which the molten plastic is extruded to form the initial shape of the pipe.
Cooling System
A cooling system is used to rapidly cool and rectify the extruded molten plastic to maintain its desired shape and size. Cooling systems can include components such as water showers, cold air blowers and cooling rollers to ensure that the pipe cools quickly and remains stable after extrusion.
Haul-Off Equipment
Haul-off equipment is used to pull the extruded jacket pipe from the die head and to control the pipe's haul-off speed to ensure consistent size and appearance. Haul-off equipment typically uses belts, straps or tyres to provide consistent traction.
Cutting Equipment
Cutting equipment is used to cut the extruded jacket pipe to the required length. Cutting can be done with knives, saws, etc., to ensure that each pipe is the exact length it needs to be.
Winding Equipment
For the production of long jacket pipes, the winding equipment is used to wind the extruded pipes into coils for easy transport and storage.
Control System
The entire production line requires a precise control system to monitor and adjust the operation of the extruder, die, cooling system, haul-off equipment and other components. Modern control systems often include automation and data acquisition to optimize the process and ensure product quality.
The Major Steps in Jacket Pipe Extrusion Machine
Material Melting
The raw materials that include pellets, powder, or granules will be loaded into the hopper. After this, the materials will be fed into the heated chamber known as the extruder. The materials will melt while moving through the extruder. Extruders will have either two or one spinning bolt.
Material Filtration
After melting the materials, the filtration process will start. The melted material will flow from the hopper through the feed throat to the spinning screw that operates within the extrusion machine. The spinning screw works in the horizontal barrel, and within that barrel, the melted material will be filtered to get a uniform consistency.
Sizing the Molten Material
The plastic material properties will vary based on the raw materials used in the process. However, all the raw materials will be processed with heat. The materials will be exposed to extreme heat at a particular temperature. The temperature level will vary according to the raw material. During the process completion, the molten plastic will be pushed by an opening that is called a die. It will enable the material to be shaped to the end product.
Workup Process
In this step, the die-cut for the profiles will be designed to have an even and smooth flow from the extruder's cylindrical profile into the last profile shape. It is worth mentioning that consistency is crucial in the plastic flow to get reliable and high-quality products.
Material Cooling
The plastic will be extruded from the die, and then it will be fed onto a belt for cooling. The belt is called a conveyor belt. After going through this step, the final product will be cooled by water or air. It is worth mentioning that the process will be similar to injection molding. But the difference is that the melted plastic will be forced by a die. But in the injection molding, the process will go through the mold.
Ways to Upgrade Your Jacket Pipe Extrusion Machine
Any worn down or aged parts in your extruder, contribute to it breaking down and working inconsistently. This in turn can result in stops for maintenance, off spec product, and delivery delays. That's why replacing aged extruder parts is a surefire way of upgrading your plastic extruder machine, and secure reliable operation without depleting your budget. Replacing a gearbox, or the electronic controls as well as screw or barrel can add a decade or more of life to your existing extruder. Moreover, since extruders are modular systems that can work with a variety of components, there's surely a part choice to fit your specific needs.
When a company is experiencing growth and an increase of production output is required, the main consideration should be to identify the "bottlenecks" of their current extrusion production line. Jacket pipe extrusion machines consist of several machines working in tandem, and it's not uncommon for the extruder machine to be the bottleneck of the line. This means that all others upstream and downstream equipment and machines in the production line (feeder, cooler, inspection equipment, puller, cutter, coiler, etc.) can operate at higher speeds but are limited to a lower speed setting due to the extruders lower capacity. In this case, great opportunity and ROI can be found in improving your extruder machines capacity, so that you can utilize your production line's full potential. And depending on your specific case and needs, improving extruder capacity could mean something as small as upgrading to a new screw & barrel or extrusion die head, to as big as installing an entirely new plastic extrusion machine.
In many cases, just upgrading your extrusion die head can offer the desired results. One example is upgrading to a multi-layer extrusion die head. This technology allows the use of scrap, recycled, and off spec raw materials for producing up to 80% of the plastic pipe, and using the more expensive virgin raw materials just for the 20% of the pipe plastic at the external layers. This provides great advantages and makes much sense in terms of ROI. Upgrading the extrusion die head is an investment with low capital requirements and quick turnaround time. And results include both economic and environmental efficiency, which is precisely what many companies are after.
Becoming more connected and digitized offers many advantages for today's plastic extrusion manufacturers. Oftentimes when you don't need to change your machine's operational characteristics but need to benefit from smart technologies, a good option is to integrate or retrofit smart PLC's to your existing machine. This way you can have more modern controls on your existing machine, real-time operation monitoring, remote control options, or advanced connectivity options. These PLCs can work standalone or in tandem with your machine's PLC, and provide a great way of modernizing operations without requiring a high investment.
At the risk of sounding like stating the obvious, the most straightforward way of upgrading an extruder is to replace it altogether. What's not so obvious is that by purchasing the right new extruder, the investment can practically pay for itself and greatly help you improve your factory's overall equipment effectiveness (OEE) across all metrics. A new extruder can be fast, work without stoppages or long changeover or setup times, and produce a minimal amount of off spec or scrap material. And on top of that, it can offer great material savings options through multi-layer extrusion. Moreover, apart from fulfilling your current requirements, investing in a new extruder can also future-proof your production for decades to come.
Choosing The Right Jacket Pipe Extrusion Machine For Your Project
Material Compatibility
The variety of materials processed by an extrusion machine should be compatible with it – whether they are conventional plastics like PVC or HDPE; or more sustainable options, for instance biodegradable polymers or those with recycled content. This relationship affects the efficiency of the process of extruding them into products.
Production Capacity
An extrusion line should match in size and capacity to the volume required by your project. High-end lines offer greater precision, which can handle larger quantities without sacrificing on quality necessary for large-scale manufacture.
Process Flexibility
Look out for adjustability features when purchasing an extruder system; this includes the ability to change between different pipe sizes or materials within short periods, thus allowing manufacturers to respond fast to market needs as well as customized orders.
Energy Efficiency
Energy consumption accounts for a significant percentage of operational costs, hence need to save power where possible. Modern extruders come designed with energy saving feature(s) that not only help cut down these expenses but also contribute towards making production processes eco-friendly.
Durability & Maintenance
Usually, top range extrusion lines are built stronger so they last longer plus require less maintenance. Investing in good quality machines can bring about considerable savings over time through reduced breakdowns and repairs, etcetera.
Technical Support & Training
After sales service is essential particularly when dealing with sophisticated models such as high-end ones used in large scale operations like pipe manufacturing; therefore ensure availability of reliable post sale support which may include provision for additional skill's enhancement through trainings among others.
How to Clean Jacket Pipe Extrusion Machine
How to clean screw properly
1. Non-dismantling cleaning method
A: Using "Resin" cleaning method
Generally used in the new equipment of the extruder after a period of time, due to part of the material remaining in the screw or barrel above the glue, the material extrusion speed is slow, and color variety color difference is large. The usual method is to replace the post-production material or degraded material, carefully clean the screw, barrel, head and die without damaging the screw. By using the chemical cleaning method, The active components of the product are activated at a certain temperature to remove these pollutants by decomposing the structure of high molecules and pigment molecules in the equipment. It also has a good cleaning effect for some "dead corner" positions.
B: Using "Non-resin material" cleaning method
In the actual production process, it is also widely accepted to use materials with certain friction and easy to crush, such as rice, corn, sawdust, toilet paper or newspaper, etc. to clean the screw. After the extruder is heated to the normal extrusion temperature, the friction generated by these substances between the screw and barrel is used to remove the resin gelation attached to the surface of the screw and the barrel. However, it is worth noting that after cleaning with this method, it is necessary to open the screw and barrel to check the cleaning condition. Under normal circumstances, it is also necessary to clean the machine again with resin cleaning material before the production of formal products.
2. Adopted the suitable heating-device
Using fire or fire baking to remove the plastic fixed on the screw is the most common and effective method in plastic processing, but acetylene flame must not be used to clean the screw. The temperature of acetylene flame can reach 3000℃. Cleaning the screw with acetylene flame will not only destroy the metal characteristics of the screw, but also significantly affect the mechanical tolerance of the screw. However, it is easy to produce black spots by burning.
3. Adopted the suitable clean method
The first step to clean the extruder is to close the discharging port at the bottom of the hopper; According to the different extrusion process, the cleaning must be realized by one person: the operator observes the screw speed and torque from the control panel and the extrusion pressure to ensure that the system pressure is not too high. Firstly, do not remove the die head for cleaning. When the extrudate is completely converted from processing resin to cleaning resin, stop the machine immediately and remove the die head, and then go in to make the residual cleaning resin flow out. Then reduce the screw speed to 15-25r / min and continue this speed until the melt flow at the front end of the die stops flowing.
How to clean barrel properly
1. When preparing the barrel for cleaning, the barrel temperature is also set at 200°C.
2. Screw the round steel brush into a drill pipe and use it as a cleaning tool on the electric drill. Then wrap the steel brush with a copper wire mesh.
3. Before inserting the cleaning tool into the barrel, sprinkle some stearic acid into the barrel, or sprinkle stearic acid on the copper wire net of the cleaning tool;
4. When the copper wire mesh enters the barrel, it starts the electric drill to rotate it, and artificially makes it move forward and backward until the movement becomes no resistance;
5. After the copper wire mesh is removed from the barrel, use a bundle of cotton cloth to wipe back and forth in the barrel to remove any cleaning resin or fatty acid residue. After several such back and forth wipe, the cleaning of the barrel is done. The thoroughly cleaned screw and barrel are ready to be assembled for the next production.
Our Factory
Our factory is strategically located, only 30 minutes away from the airport and port.
Ultimate FAQ Guide to Jacket Pipe Extrusion Machine
Q: What is the application of jacket pipe extrusion machine?
Q: What are the Benefits of Using a Jacket Pipe Extrusion Machine?
Q: What are the Process of Jacket Pipe Extrusion Machine?
Q: How to clean jacket pipe extrusion machine?
Q: What are the Critical Components Of A Jacket Pipe Extrusion Machine?
Q: What are the Emerging Technologies In Jacket Pipe Extrusion Machine?
Q: Why does The current of the host is unstable?
Q: Why does The temperature rise of main motor bearing is too high?
Q: Unstable machine head pressure
Q: Why does the oil pressure is always Low?
Qingdao Kruto Plastic Machinery Co., Ltd. is one of the most professional jacket pipe extrusion machine manufacturers and suppliers in China, featured by quality products and good service. Please rest assured to buy customized jacket pipe extrusion machine at competitive price from our factory.
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