Extrusion Asia Edition 1-2025

EXTRUSION & RECYCLING ASIA 1/2025 Andreas Türk总结道：“由于将能源和原材料成本降至最 低，我们的管材挤出生产线在经济上非常有吸引力。NG系 列的工艺工程设计也提高了产品质量，最大限度地减少了废 品和超重。这是一个经济和生态双赢的解决方案。”。 关于巴顿菲尔辛辛那提 巴顿菲尔辛辛那提公司是一家领先的挤出设备制造商，可 根据客户的具体要求生产节能高效的挤出机和完整的挤出生 产线。 为管材、型材、板片材、热成型和造粒挤出领域的广泛 应用，提供量身定制的解决方案，其产品组合包括单螺杆 和双螺杆挤出机、模具、下游设备、扩口机和扩口机喂料 器。客户由德国、奥地利、中国和美国的生产基地以及全 面的全球销售和服务网络提供服务。巴顿菲尔辛辛那提的 客户受益于德国、奥地利、中国和美国生产基地，以及遍 布全球销售和服务网络。 PIPE EXTRUSION 使用solEX挤出机、螺旋II模具和下游设备 vacStream、coolStream、pullStream和 cutStream生产PO管材的完整生产线 T he extruder is not only one of the most important core components in every pipe line, but also the largest energy consumer, accounting for up to 80% of total energy consumption in some cases. “Thanks to the process engineering design of the new solEX NG single-screw series, we have managed to reduce energy consumption by around 15% compared to previous generations,” emphasizes Andreas Türk. The main reason for this improvement is the internally grooved barrel, which has a low axial pressure pro le in combination with the matching screw geometry. This leads to both reduced energy consumption and less machine wear. At the same time, the new processing unit ensures a very gentle and homogeneous melting performance at around 10 °C lower temperatures. The second core component of every pipe line is also indispensable: the helix dies from battenfeld-cincinnati not only score points with the unique and patented process engineering combination of screen basket distributor and spiral mandrel, but due to their design also with 10% lower energy costs for the heating capacity compared to conven - tional pipe heads. In addition, the screen basket homog - enizes the melt thermally and mechanically, which leads to a further improvement in product quality. The third im - portant factor in uencing the overall energy consumption of a pipe line is the cooling and therefore the downstream units, consisting of vacuum tanks and spray baths. The green line concept works with frequency-controlled pumps and a very e cient water supply, both of which help to reduce energy costs. With an energy-e cient complete system set-up consist - ing of solEX NG, helix die and green line downstream equip - ment, around EUR 85,000 in energy costs can be saved per year, calculated with 7,000h production p.a. and 12 Euro - cent per kWh, when producing a 250 mm PO pipe with SDR 11 and an output of 1,000 kg/h. With a conventional energy mix, this corresponds to a CO2 equivalent of 315,000 kg. As with the energy costs of the extruders, material con - sumption is the main factor in uencing production costs: around 85% of production costs are attributable to the raw material used. “For ecological and economic reasons, we have to make sure that little scrap is produced, and that the production of good products is carried out within the nar - rowest tolerances,” says Andreas Türk, explaining that the line components from battenfeld-cincinnati are designed precisely for this purpose. Thanks to the combination of the screen basket distributor and the spiral mandrel of the helix pipe heads, the melt is distributed more precisely, which is particularly evident with thicker wall thicknesses. Due to the improved melt quality, the tolerance ranges of the wall thicknesses in the pipe can be signi cantly re - duced. In addition to the gravimetric dosing system, which ensures exact quantity dosing, and the extruder, which works with a minimum throughput uctuation, the inline wall thickness control and the centering aid inside the die head are also responsible for exact wall thickness distri - butions and low tolerances in the pipe lines. Precise wall thickness distributions in turn minimize material consump - tion. Here is an example: If the target wall thickness of 6.2 mm of a 200 mm PO pipe with SDR 33 varies within a nar - row tolerance range between 6.22 and 6.48 mm instead of the usual up to 7 mm, around 1 million euros in raw material costs can be saved per year at a throughput rate of 1,000 kg/h and calculated with 1.50 Euro per kg/HDPE and 7,000h production p.a. Due to the design of the tools fast color change times support the raw material savings. Complete system to produce PO pipes with the solEX extruder, the helix II tooling and the downstream systems vacStream, coolStream, pullStream and cutStream 25