What Is The Process?
The extruder takes the raw plastic material in either pellet or powder format and is heated and forced through a forming die in the shape of a pipe or profile such as window frames. The cooling is achieved by either an initial bath or spay booth with cooling water to ensure it takes on its correct shape.
If the Pipe or profile is likely to lose its form either because of its intricacy or weight the first stage will be a vacuum bath which has a vacuum pump together with a cooling spray bath to ensure that the product stays in shape. Pullers pull the material (gently) through the process where it meets a winding machine ready for packing as the finished product.
Product examples: Plastic pipe, window frames or plastic casing on cables.
Full Turnkey Solutions
Aqua’s aim is to build a life-long relationship with our customers, becoming essentially a “one stop shop” for all your temperature control requirements, for now and the future. The three divisions of our business – Sales, Hire & Service – enable us to help clients every step of the way.
Our USP is our ability to offer clients a complete turnkey solution. We’ll work with you from initial site visit and system design to installation and commissioning. Our services include:
- Free design consultancy, including AutoCAD drawings, 3D modelling and energy calculations
- Mechanical and electrical installation – encompassing civil works, offloading & positioning, pipework installation, mains power and cabling, all CDM compliance, full project management and delivery
- Aftersales support – including preventive maintenance plans to maximise product lifespan and efficiency
Our business is built on our core values of technical excellence, care, integrity and a “can do” attitude. We train all our people to be specialists in what they do – innovative engineers dedicated to providing practical, effective and efficient solutions supported by second-to-none customer service.
Typical Products Used In The Packaging, Plastics & Rubber Industry
Pipe Extrusion Cooling Considerations
- What is the temperature of the chilled water required?
- What water pressure do you require at the tools?
- What is your plastic throughput/hour?
- What type of plastic is being used?
- What is the in/out differential?
- What is the method of water return?
- What is the vacuum pump size?
Why Is Cooling Required For The Pipe Extrusion Cooling Process?
The purpose of the cooling tank is to cool the plastic from a soft state to a hard state. To achieve this it removes the heat by transferring into the water directly from the product. A cooling system is required to remove the heat from the water tank but because the cooling water is in direct contact with the product and therefore either swarf from the finished product or even the raw product can get into the water. A heat exchanger or sophisticated filter system must be used between the cooling baths and the chiller system.
As already stated with profile or larger pipe extrusion the shape might collapse before being cooled and therefore it will go through a vacuum cooling bath before the normal cooling bath to ensure that the shape is maintained. The vacuum is created by a normal water pump sucking from the chamber but it operates extremely inefficiently and therefore the total power must be included in the load calculations.
How The Cooling Is Calculated
Tools = Plastic through put x Plastic Factor = Cooling Duty in KW
Vacuum pump kW = cooling duty in kW
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Why Call Aqua?
Established in 2001, Aqua Group are a market leading force in the design and supply of innovative temperature control solutions. Our team has a vast product knowledge base and years of application experience and is focused on finding the most energy efficient and price competitive solution for your specific business needs.
Whether you’re an end user looking for a bespoke cooling system design or a trade customer trying to source a single chiller unit, our specialist engineers are on hand to help. Aqua Group’s core values – Technical Excellence, Can-do Attitude, Integrity and Care – are at the heart of everything we do, and we always strive to achieve the highest level of customer service experience.
For help with product selection and technical advice call our sales team today on 0333 004 4433.