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Help CenterDual-Layer Corrugated Pipe Production Line With Integrated Cooling and Diameter Control
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HDPE/PP Double Wall Corrugated Pipe Extrusion Line
This machine is mainly to produce the HDPE/PP or PVC double wall corrugated pipe for non pressure application, such as drainage pipeline, sewer pipeline,etc.
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Feature:
Advanced single-screw extruder with highspeed, high-efficiency and thorough plastization Special structure forming head make the thickness of the interior and exterior wall even, and stable molding. In addition, the thickness of interior and exterior can be adjusted.
Corrugation system with supper mold block cooling system ensures high extrusion speed in continuous production.
Equipped supper vacuum system to ensure the corrugation forming quality.
Advanced Lubrication System makes the abrasion of mold block to the least and ensures corrugator and mold block long service life and the precision of operation and the steady quality of production.
Advanced dual-layer socket belling inline system is equipped.
Suitable for variety of material: HDPE, PP, PVC
Specification
Model |
Diameter(mm) |
Speed m/min |
BWG-250 |
Ø90-Ø250 |
0.2-15 |
BWG-600 |
Ø200-Ø600 |
0.2-5 |
BWG-800 |
Ø200-Ø800 |
0.1-5 |
BWG-1200 |
Ø500-Ø1200 |
0.1-5 |
Detailed Product Features & Technical Specifications:
The production line is a comprehensive system built for reliability and high output. Its core innovation lies in the synchronized control of the dual-layer extrusion and the corrugation forming process, coupled with a proprietary cooling system that stabilizes the pipe dimensions immediately after forming.
Dual-Layer Co-Extrusion: Utilizes two independent extruders (typically twin-screw) for the inner and outer layers. This allows for material optimization—using a virgin material for the outer wall for UV and chemical resistance, and a recycled or different grade material for the inner layer, reducing overall material cost without compromising performance.
Integrated Cooling & Diameter Control Unit: This is the heart of the line. A closed-loop control system constantly monitors the pipe diameter via laser sensors. The integrated cooling system, combining water spray and air knives, is dynamically adjusted based on the sensor feedback to ensure the pipe sets to the exact target diameter, minimizing post-production shrinkage and ovality.
Precision Corrugation Molding: Features a modular corrugator with interchangeable mold blocks, allowing quick changeovers for different pipe diameters and corrugation profiles (e.g., single-wall, double-wall profiles). The mold blocks are precision-machined and often coated for extended life and easy release.
Centralized PLC Control: The entire line is managed from a centralized control panel with a user-friendly touchscreen HMI. Operators can set parameters, monitor real-time production data (speed, temperature, diameter), diagnose issues, and store recipes for different products.
High-Efficiency Vacuum Calibration & Cooling Tank: Following the corrugator, the pipe enters a multi-stage vacuum calibration tank. This ensures the inner layer's smooth bore is perfectly calibrated and cooled uniformly, which is critical for maintaining hydraulic flow efficiency in drainage pipes.
Automatic Haul-Off & Cutting: A caterpillar haul-off unit provides constant, tension-controlled pulling force. An integrated traveling saw cuts the pipe to pre-set lengths with clean, burr-free edges, ready for packaging or further processing.
Advantages & Client Benefits:
Superior Product Consistency: The integrated diameter control eliminates diameter drift, ensuring every meter of pipe meets strict dimensional tolerances, which is vital for coupling compatibility and system performance.
Increased Production Efficiency: The rapid and controlled cooling significantly reduces the cooling time required, allowing for higher line speeds and greater daily output compared to traditional lines with separate cooling stages.
Material & Energy Savings: Precise control over the extrusion and cooling process minimizes material waste from off-spec products. The optimized cooling system also reduces water and energy consumption.
Operational Simplicity & Reduced Labor: The automated, centralized control requires fewer operators. Recipe storage allows for quick changeovers between different pipe sizes, minimizing downtime.
Enhanced Pipe Performance: Produces pipes with excellent layer adhesion, high ring stiffness (SN ratings), and superior impact resistance, making them suitable for demanding buried applications.
Trust & Proven Global Delivery:
Qingdao Yongke Machinery operates from a modern facility spanning 10,000-30,000 square meters, backed by a dedicated team of 51-100 professionals. Our commitment to quality is formalized through ISO9001, ISO14000, and OHSAS18001 management systems, ensuring every production line is built to exacting standards. With an annual export value ranging between US$1 Million and US$1.5 Million, our machines are trusted in diverse markets across North America, South America, Europe, Asia, Africa, and Oceania, shipped efficiently from the Port of Qingdao.
This Dual-Layer Corrugated Pipe Production Line embodies our mission to provide robust, innovative, and cost-effective manufacturing solutions. It is not just a machine; it's a partnership in enhancing your production capability and product quality. We invite you to contact us to discuss your specific requirements, explore customization options, and see how this integrated line can become the cornerstone of your corrugated pipe production.
Frequently Asked Questions (FAQ):
Q1: What is the main advantage of a dual-layer pipe over a single-layer pipe?
A: Dual-layer pipes combine the benefits of two different materials or grades. Typically, a tougher, UV-resistant outer layer protects against environmental stress, while a smoother, more cost-effective inner layer optimizes flow or provides specific chemical resistance. This structure offers enhanced ring stiffness and durability, often at a lower overall material cost than a single-layer pipe of equivalent performance.
Q2: How does the integrated diameter control system work?
A: The system uses non-contact laser measuring heads placed after the corrugator and cooling zones. These sensors provide real-time diameter data to the PLC. The PLC then automatically adjusts the speed of the haul-off unit and/or the cooling intensity (water flow/air volume) to correct any deviation from the setpoint, ensuring consistent pipe dimensions.
Q3: Can this line produce pipes with different corrugation profiles?
A: Yes. The corrugator is designed with modular mold blocks. Changing the profile involves replacing these mold blocks. Our team can supply different mold sets for various standard profiles (like N-12, S-16 for drainage) or even custom profiles based on your design.
Q4: What is the typical lead time for such a production line?
A: The lead time depends on the specific configuration, level of customization, and current production schedule. Generally, for a standard configuration, it ranges from 60 to 90 days after order confirmation and receipt of deposit. A detailed schedule is provided upon quotation.
Q5: Do you provide installation and training services?
A: Yes. We offer comprehensive after-sales support. This typically includes supervision of installation and commissioning by our experienced engineers at your factory site, as well as detailed operational and maintenance training for your technical staff. Remote support is also available.
Q6: What materials can be processed on this line?
A: The line is primarily designed for polyolefins like HDPE (high-density polyethylene) and PP (polypropylene), which are most common for corrugated pipes. It can also be configured for PVC. The specific extruder configuration (screw design, L/D ratio) can be optimized based on your primary material choice.
Q7: How is the line shipped, and what are the packaging details?
A: The line is disassembled into major modules (extruders, control panel, corrugator, tanks, haul-off) for shipping. Critical components are packed in wooden crates for protection during sea freight. All packaging is export-standard, suitable for long-distance transportation.
Q8: Can the production speed be adjusted?
A> Absolutely. The production speed is fully adjustable via the touchscreen HMI. The maximum achievable speed depends on the pipe diameter, wall thickness, and material. The PLC ensures all downstream units (corrugator, cooling, haul-off, cutter) synchronize perfectly at any set speed.
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