Barton Fil Cincinnati has delivered large pipeline production lines to Egypt. These two production lines, capable of manufacturing large polyethylene (PE) pipes with a diameter of up to 2.7 meters, have recently been installed at the facilities of two customers in Egypt, and the first phase of the project has successfully commenced production.
"With the help of Battenfeld-Cincinnati's new production line, the large-diameter pipes we produce are of excellent quality and precision," commented Ahmed Mahalevy, the owner of Cairo Plastic Pipes and Products Company (PPP), about the German-Austrian joint venture equipment manufacturer.
PPP has just completed a project in Oman: high-quality pipelines deliver seawater to a desalination plant—a scenario that is ideal for plastic pipes, where their corrosion resistance plays a crucial role.
Uniform wall thickness reduces material consumption
In the production of large-diameter pipes, material cost is often the area with the most potential for savings. "Our core technology lies in reducing wall thickness tolerances. Through extensive optimization of various system components, we can now easily achieve tolerance values that are only half of the DIN standard," explained Andreas Dirke, Sales Director at battenfeld-cincinnati. By relying solely on this dimensional precision and minimized wall thickness deviations, compared to traditional production lines and deviation ranges, a single production line can save over 1 million euros in raw material costs annually.
Other advantages of our technology also include a high output rate of 2 tons or more per hour, equipment design life of 20 to 25 years, and low energy consumption. This means that the investment can be recouped in a very short period of time," Andreas Tilke added.
Coordinated synergy of each component
These advantages stem from the overall process design of the system: all independent components work in perfect coordination, and, combined with a modern, intuitive control system, ensure the reliability of input and configuration.
During the extrusion process of large-diameter pipes, melt temperature is crucial — it is the main cause of unnecessary sagging in the pipes. Andreas Tilke explains: "The lower the polyethylene melt temperature, the higher the viscosity, and the less sagging occurs; the less sagging, the better the pipe quality and wall thickness distribution." In the solEX NG extruder, the combination of the grooved barrel with the matched screw and groove liner geometry enables a high specific output at low screw speeds, thereby reducing the melt temperature. Compared to the previous generation of extruders, the melt temperature is lowered by approximately 10°C; additionally, the OptiMelt active melt cooling system installed between the extruder and the die can further reduce the temperature by about 10°C.
In addition, the two-stage VSI die head (a combination of a spiral core rod distributor and a filter basket) patented by Battenfeld Cincinnati is, according to the company, capable of ensuring uniform distribution of the melt within the die, thereby achieving uniform cooling and an extremely narrow wall thickness deviation range.
Balancing energy and resource efficiency
Thanks to the precise design of each component, high-quality large-diameter pipes can be produced through energy-saving methods. All downstream equipment (suitable for various pipe sizes up to 2.7 meters in diameter) features low energy consumption and low water usage designs, contributing to energy conservation and efficiency improvement. In the vacuum cooling tank, the pipes can also be cooled individually in segmented sections along the circumference, a function that further optimizes wall thickness distribution and minimizes ovality.
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