PIPE extrusion plants

PLASTICS PROCESSING TECHNOLOGY

EXTRUSION TECHNOLOGY

PIPE EXTRUSION PLANTS

AMERICAN MAPLAN CORPORATION

PIPE EXTRUSION PLANTS

TABLE OF CONTENTS
Page Automation Single screw extruder Twin screw extruder PO dies PVC dies Vacuum calibrators and spray cooling baths Calibration sleeves Haul-off units Cutting devices Belling systems Twin strand extrusion Steel pipe jacketing 4 - 5 6 7 8 - 9 10 - 11 12 13 14 - 15 16 - 17 18 19 20

AMERICAN MAPLAN CORPORATION

PIPE EXTRUSION PLANTS

AUTOMATED MACHINE LINES

Faster, higher output, more economical these are the market requirements placed on pipe extrusion plants. These coincide without exception in plant development. This is the primary reason why American Maplan is the market leader in pipe extrusion equipment production. Our customers benefit from our core competency in the manufacture of complete extrusion lines and also from the experience gained in the development of intelligent automation solutions.

The functions of all plant elements are harmonized and equipped with efficiently operating automation systems. We supply technology meeting the highest requirements so that you can produce the best possible quality.

AMERICAN MAPLAN CORPORATION

PIPE EXTRUSION PLANTS

AUTOMATION

OUR CONTROL SYSTEMS BMC offers: Central and efficient operation Reproducible production Documented quality Automation of the entire machine line

OUR CONTROL SYSTEMS American Maplan tele-maintenance provides the fastest support of operating personnel worldwide in diagnosis, optimization of process parameters and malfunction remedy. Production downtime is minimized because the knowledge of our qualified personnel is directly available on site.

Line 1

Line 2

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AMERICAN MAPLAN CORPORATION

PIPE EXTRUSION PLANTS

CONTROL SYSTEM Well arranged and simple: the easily configurable control surface in combination with the stepped automation concept ensures efficient operation in all areas of pipe extrusion. The integration of system extensions, such as dosing systems, co-extruders, melt pumps and an intelligent sensor system in the central control system is possible. The control system is complemented by its network integration and tele-maintenance capabilities. STEP II IN AUTOMATION The efficiency of the system can be increased by the integration of an intelligent gravimetric sensor system. One main and up to five secondary components per extruder are possible. In addition, the weight per metre of the product is kept constant at all times by a stabilized mass throughput and the slaved take-off speed. STEP III IV IN AUTOMATION The integration of ultra-sonic measuring chambers allows further advantages in pipe production, as product monitoring and documentation are notably improved and manual centering is simplified. Optionally, thermal centering tools can be implemented in the automation process. Last but not least, the possibility of minimum wall thickness variation generates a further reduction in material consumption.

User friendly operation

Dosing station

Weigher

Wall thickness display

Ultra-sonic measurement

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PIPE EXTRUSION PLANTS

SINGLE SCREW EXTRUDER

HIGH PERFORMANCE EXTRUDER Be it maximum output in special application fields or extreme versatility the single screw extruders from American Maplan are chosen because of their industry-leading technology and the easy integration with all extrusion components.

GROOVED FEEDBUSH For the extrusion of polyolefin pipe in particular, the American Maplan extruders are equipped with a grooved feedbush. In combination with a barrier screw, this means that particularly plastification outputs are achieved at an excellent homogeneity of the melt.

Single screw extruder For specication, please refer to the technical report. Type
Output [kg/h]

1-45-30B
220 - 240

1-60-30B
370 - 400

1-75-30B
540 - 580

1-90-30B
750 - 800

1-120-30B
1100 - 1200

1-150-30B
1500 - 1700

1-220-30B
2000 - 2300

Performance information depending on pipe dimensions and material type.

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PIPE EXTRUSION PLANTS

TWIN SCREW EXTRUDER

28D PROCESSING UNIT American Maplan has set new standards in PVC extrusion by the development of their processing units. The processing technology is distinguished by its improved product quality, higher output and an enormous processing range.

COMPETENCY Highlights of the American Maplan twin-screw extruders: Compact design Screw temperature control via sealed water or active oil Heating with ceramic heating bands Barrel cooling by means of air blowers or tempered fluid Stuffer for screw rotational speed reduction Screw rotational speed

Single screw extruder For specication, please refer to the technical report Type
Output [kg/h]

CON 40
5 - 60

BEX 54
20 - 130

DSK 62
30 - 300

TS 92
140 - 550

BEX 92
150 - 350

TS 100/2
160 - 650

TS 110
250 - 800

TS 135

BX 168

450 - 1650 110 - 2300

Performance information depending on pipe dimensions and material type

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PIPE EXTRUSION PLANTS

Dies for POLYOLEFIN PIPE EXTRUSION

Whether for the transport of water or gas, or for any industrial use, multi-layer polyolefin pipes are defined by their flexibility and variability. In this field, American Maplan offers a wide range of dies for the selection of the right solution for every requirement. VSI SCREEN DIES Lattice basket dies are used for the extrusion of HDPE, LDPE, HMW-PE, PP , ABS and PS. Advantages: Low melt pressure and temperature, even at high throughput Good homogenization by the two-stage distribution concept, consisting of a spiral thread and a compact lattice basket Consistent product quality at all pipe dimensions Large processing range with multiple material viscosities Short purge times by designing short dwell time into the die

Lattice basket dies For specication, please refer to the technical report Type
Pipe diameter [mm] Max. throughput [kg/h]

PO 32/350
10 - 32 350

PO 63/400
16 - 63 400

PO 125/450
25 - 125 450

PO 25/700
50 - 250 700

Type
Pipe diameter [mm] Max. throughput [kg/h]

PO 450/800 PO 630/900 PO 800/1000 PO 1000/1000 PO 1200/1200 PO 1400/1200 PO 1400/1300

90 - 450 800 200 - 630 1000 315 - 800 1200 450 - 1000 1200 630 - 1200 1200 710 - 1400 1200 710 - 1600 1200

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PIPE EXTRUSION PLANTS

MULTI-LAYER DIES Pipe properties can be optimized in a targeted manner by co-extruding several materials. The correct die depends on the individual application. American Maplan develops and produces dies for the widest range of co-extrusion applications optimally matched to the specific product requirements. RADIAL DISTRIBUTOR WITH SCREEN PLATE This low-cost die is particularly characterised by its robust and compact construction design. The additional screen plate improves the distribution and homogenization of the melt similar to the lattice basket by providing a double deflection. In conjunction with the proven lattice basket in the main layer, a wide application range is guaranteed at all times. LATTICE BASKET DIE WITH THREE LAYER SPIRAL MANDREL DIE While the lattice basket with its known advantages is used for the thicker center layer, frequently consisting of a low-cost material, the spiral mandrel die finds its application to meet the high requirements of the surface quality for thin inner and outer layers. FIVE LAYER SPIRAL MANDREL DIE Meets the requirements for the production of PO hot water pipes. Advantages: Ideal homogeneity and wall thickness distribution of all 5 layers Highly compact tool design Relatively short flow paths from the extruder to the die exit

AMERICAN MAPLAN CORPORATION

PIPE EXTRUSION PLANTS

Dies for PVC PIPE EXTRUSION

For sensitive PVC materials, American Maplan counts on flow-optimized single and double spider dies. Both die types guarantee uniform melt distribution throughout the entire pipe circumference in an ideal manner.

SPIDER DIES For PVC processing, the geometric die design offers the following advantages: Very good flow properties throughout the entire flow channel Ideal dwell time spectrum with targeted temperature control of the sensitive material

Spider dies For specication, please refer to the technical report Type
Pipe diameter [mm] Max. throughput [kg/h]

RK 1
16 - 50 175

RK 1.5
16 - 75 575

RK 2
40 - 90 625

RK 3
75 - 160 775

RK 4
1075

RK 5
1350

RK 5.5
1800

RK 6
1800

RK 6.5
1800

140 - 280 225 - 355 315 - 500 355 - 630 400 - 800

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PIPE EXTRUSION PLANTS

FOAM CORE PIPE ADAPTER The sophisticated concept of the co-extrusion adapter permits the production of weight-reduced foam core pipe as well as pipe with a compact center layer made of low-cost reclaim. The pipe is shaped as usual by a conventional PVC spider die. The special design of the adapter permits optional operation with one or two co-extruders for the compact inner and outer layer.

DOUBLE SPIDER DIE The PVC double spider dies are a further development offering the following advantages: Low pressure build-up Higher volume within the die Larger dimensional range Higher throughputs No continuous spider die marks Better mechanical properties

Double spider dies For specication, please refer to the technical report Type
Pipe diameter [mm] Max. throughput [kg/h]

RD 0.5-4
16 - 110 450

RD 1-7
15 - 175 1000

RD 2-10
50 - 280 1200

RD 6-18
150 - 450 1800

RD 12-27
300 - 710 2500

RD 15-36
355 - 1000 2500

RD 24-48
630 - 1300 2500

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PIPE EXTRUSION PLANTS

VACUUM CALIBRATORS and SPRAY COOLING BATHS

SINGLE/DOUBLE CHAMBER VACUUM CALIBRATORS A new generation of vacuum calibrators with desirable features: Patented fast vacuum regulation Precise temperature control Flow optimized pipework made of stainless materials Vacuum limiter Cold water temperature control Circulation and vacuum pumps Double filter unit

SPRAY COOLING BATHS Performance features: Circulation pump Filter with manual return via bypass Temperature control via thermostat valve in the water supply Central water drain Temperature display Water collector at the intake and outlet

Vacuum calibrators and spray cooling baths For specication, please refer to the technical report
Type V 63 VA - 6m V2-63 VA - 6m V2-63 VA - 9m CB 63 VA - 6m
10 - 63

V 125 VA - 6m V2-125 VA - 6m V2-125 VA - 9m CB 125 VA - 6m

20 - 125

V 160 VA - 6m V2-160 VA - 6m V2-160 VA - 9m CB 160 VA - 6m

20 - 160

V 250 VA - 6m V2-250 VA - 6m V2-250 VA - 9m CB 250 VA - 6m

40 - 250

V 500 VA - 6m V2-500 VA - 9m CB 500 VA - 6m

90 / 140 - 500

V 400 VA - 6m V2-400 VA - 6m V2-400 VA - 9m CB 400 VA - 6m

50 - 400

Pipe diameter [mm]

Type

V 630 VA - 6m V2-630 VA - 9m CB 630 VA - 6m

V 800 VA - 6m V2-800 VA - 9m CB 800 VA - 6m

200 / 400 - 800

V 1000 VA - 6m V2-1000 VA - 9m CB 1000 VA - 4m

200 / 450 - 1000

V 1200 VA - 6m V2-1200 VA - 9m CB 1200 VA - 4m

315 / 630 - 1200

V 1400 VA - 6m V2-1600 VA - 12m V2-1400 VA - 9m CB 1400 VA - 4m CB 1600 VA - 6m

315 / 60 - 1400 710 - 1600

Pipe diameter [mm]

110 / 140 - 630

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PIPE EXTRUSION PLANTS

The right CALIBRATION SLEEVE for every application

American Maplan supplies calibration inserts for all technical plastic materials. Advantages: Excellent heat conductance High wear resistance Good glide properties High production output Calibration sleeves For specication, please refer to the technical report Type
Material Diameter [mm] Cooling principle

I
PC, ABS, PS 10 - 1000 Intensive cooling

II
HDPE 32 - 110 Intensive cooling, adjustable water ring

IV
PO, PB, PA 32

V
PP , PE-MD/LD 32

VI
HDPE 110 - 1600 Dry inlet and spray cooling

Disc calibration with Intensive cooling, adpre-chamber; optional: justable glide cooling spray ring

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PIPE EXTRUSION PLANTS

HAUL-OFF UNITS

The suitable haul-off for every requirement: American Maplan offers: Belt haul-off units for small PO pipe at high production speed Caterpillar haul-off units predominantly for pipe of a small to medium diameter Multiple caterpillar haul-off units for thin-walled and larger pipe

MULTI-MOTOR TECHNOLOGY As far as drive systems are concerned, American Maplan counts on an ultra-modern technology consisting of a digital controller and a separate AC servo drive at each caterpillar. This means the haul-off speeds can be precisely synchronized. The system is characterized by the following performance criteria: A mechanical power distribution is no longer required Improved efficiency Optimization of production

Multiple caterpillar haul-off units For specication, please refer to the technical report
Type
Pipe diameter [mm]

R 125/3+1 VE
10 - 63

R 125/4
20 - 125

R 125/3 VE R 160/3+1 VE R 160/3 VE

20 - 160 20 - 160 32 - 160

R 250/4
20 - 250

R0 250/6
50 - 250

R 400/4 E
48 - 400

R 400/6 E
75 - 400

Type
Pipe diameter [mm]

R 500/4
50 - 500

R 500/6
75 - 500

R 630/6
75 - 630

R 630/8
75 - 630

R 800/6
160 - 800

R 1000/8
250 - 1000

R 1400/10
500 - 1400

R 1600/10
300 - 1600

R 2000/12
500 - 2000

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PIPE EXTRUSION PLANTS

DOUBLE CATERPILLAR AND BELT HAUL-OFF UNITS Precise synchronization by AC servo drives Parallel guidance of the oscillating top belt/caterpillar at the front side Pneumatic contact pressure by dual cylinders Belt haul-off units for high extrusion speeds of >25 m/min

MULTIPLE CATERPILLAR HAUL-OFF UNITS The multiple caterpillar haul-off units are suitable for almost all pipe diameters. Advantages: Wide segments Long contact length High haul-off forces

Belt haul-off units For specication, please refer to the technical report Type
Pipe diameter [mm]

P 50 BVE
10 - 40

P 100 BVE
10 - 63

P 160 BVE
10 - 110

Twin caterpillar haul-offs For specication, please refer to the technical report Type
Pipe diameter [mm]

R 50 SE
25 - 63

R 100 SE
25 - 90

R 160 SE
25 - 125

R 250 SE
32 - 250

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PIPE EXTRUSION PLANTS

CUTTING DEVICES

American Maplan offers cutting devices that meet all requirements. Our range encompasses upstroke saws, planetary cutters and automatic pipe cutters. PLANETARY SAWS Performance features for circulating saws and cutters: PVC pipes, chip removing cutting and bevelling on one or both sides PVC foam core pipes, chip removing bevelling first, followed by cutting without chips

PO pipes, chip removing cutting with a special saw blade Depending on the design, the saw carriage is equipped with a pneumatic drive or a servo drive

Planetary saws For specication, please refer to the technical report Type
Pipe diameter [mm]

STU 125
25 - 63

STU 160
16 - 160

STU 250
40 - 250

STU 500
75 - 500

STU 800
160 - 800

SU 1000
250 - 1000

SU 1400
300 - 1400

SU 1600
300 - 1600

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PIPE EXTRUSION PLANTS

PLANETARY CUTTING DEVICE Performance features for PE and PP pipe cutting without chips: Pneumatic saw carriage advance Basic equipment for jaw clamping Guide conveyor in the infeed as a roller table, in the outfeed as a V channel, central, mechanical height adjustment Integrated PLC control system/operation AUTOMATIC PIPE CUTTER Fast conversion to a different pipe dimension and cutting techniques Minimal noise cutting process Cutting of PO pipe without chips Chip removing cutting and bevelling of PVC pipe Cutting without chips and chip removing bevelling of PO pipe

Planetary cutting device For specication, please refer to the technical report Type
Pipe diameter [mm]

TU 125
0 - 125

TU 160
16 - 160

TU 250
40 - 250

TU 500
90 - 500

TU 800
160 - 800

Automatic pipe cutter For specication, please refer to the technical report Type
Pipe diameter [mm]

RTA 63
10 - 63

RTA 125
20 - 125

RTA 250
50 - 250

RTA 500
90 - 500

RTA 800
250 - 800

RTA 1200
500 - 1200

UPSTROKE SAWS Pneumatic saw blade advances vertically upward Efficient chip extraction Saw hood with integrated clamping above the saw table

Upstroke saws For specication, please refer to the technical report Type
Pipe diameter [mm]

SPR 63 P
63

SPR 63 E
63

SPR 125 P SPR 125 E SPR 125 H SPR 250 P SPR 250 E
125 125 125 250 250

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PIPE EXTRUSION PLANTS

BELLING MACHINES

An American Maplan construction series of belling machines covers all fields of application. Heating and forming methods adapted to the most varied pipe materials not only guarantee a consistently high product quality, but also an optimal output matched to each extruder. Pipe stackers and bundling devices complete the range with regard to economical and highly productive extrusion. NEW HEATING SYSTEM AWI PLUS (Pat. pend.) Substantial reduction of the heating time No thermal deterioration of the pipe Absolutely uniform pre-heating Operating temperature reached within one second High energy saving

PVC pipe 9 machine types from 10 to 1200 mm PE and PP pipe 5 machine types from 32 to 630 mm RIEBER sealing ring 5 machine types from 50 to 1200 mm

Rieber belling unit

Belling machines For specication, please refer to the technical report

Type
Pipe diameter [mm]

KK 70/2 A
10 - 75

KM-D 125 A
25 - 125

KM-D 160 A
50 - 160

KM-D 250 A
50 - 250

KM-D 500 A
110 - 500

KM-D 650 A
180 - 630

KM-D 800 A
180 - 800

KM-D 1000 A
280 - 1000

KK-D 1200 A
400 - 1200

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PIPE EXTRUSION PLANTS

TWIN STRAND EXTRUSION

Twin strand pipe extrusion is to be recommended where high throughputs are to be achieved with small pipe diameters. Advantages: Independent speed control per strand Possibility to produce different diameters at the same time Twin strand lines with two independently controlled downstream units

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PIPE EXTRUSION PLANTS

STEEL PIPE JACKETING

Polyethylene is best suited to protect steel pipe from corrosion. American Maplan offers two extrusion methods for PE jacketing: Pipe jacketing for smaller pipe diameters Pipe wrapping is used for larger pipe diameters PIPE JACKETING For pipe jacketing, the pretreated pipe is continuously guided through a cross extrusion die while the melt is applied to the pipe by vacuum.

PIPE WRAPPING For pipe wrapping, a first extruder extrudes the coupling agent as a film layer, while a second extruder applies the multi-layer PE wrap. A homogeneous compound material is achieved by the high pressure applied as the wrapping layers are placed on the pipe surface.

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AMERICAN MAPLAN CORPORATION

PO Box 832 McPherson, KS 67460 Phone 620 241 6843 Fax 620 241 0207 E-mail: welcome@maplan.com Internet: www.maplan.com

BEX 09/04, RT, E, FSW, 4203 . Kay . Printed in Germany

Subject to change