Pipe Extrusion

Classic Line – for PVC Pipe

The classic line extruders have been used successfully for many years. Despite having introduced new machines Weber will continue to offer these classic models to ensure compatibility with existing equipment.

Extruder	Max.ouput PVC Pipe kg/h
DS72.22	240
DS9.25	450
DS11.27	850
DS12.28	1000
DS13.27	1100
DS15.22	1800
CE5.2	100
CE7.2	250
CE8.2	300

   

New DS 32 D Series : Maximum Performance for PVC Pipe

The new extruders series DS 32 D is equipped with powerful drive technology and an innovative screw design.

Weber have developed a brand new screw design which produces extremely high plastification, it is especially advantageous  for the extrusion of uPVC pipes. It generates earlier plastification and thus allows for greater throughputs with smaller L/D ratios than currently on the market today.  

On top of that it produces such a good dispersion that the Calcium Carbonate filler can be dosed and mixed directly on top of the extruder and then fed directly into the screw flights and is homogenized and plasticised in the barrel. As the filler content in dryblend is limited because of segregation, the direct dosing of additional filler and processing by means of the new screw design is the answer to achieve a stable and reliable process and an excellent pipe quality of highly filled PVC pipes.

As an example, a 90mm twin screw extruder DS9.32 can produce 110mm diameter pipe with a *filler level of 20 parts at upto 800kgs/hr.

With this screw geometry Weber have also proved that it can process with *filler levels of 50 parts at an output of upto 650kgs/hr. The dispersion of the filler is exceptional which means this pipe passes all of the standard tests of lower filled pipe.

*CaCO3

This new screw geometry allows for :-

• Higher output
• Improved product quality
• Lower raw material costs
• Cold mix – directly dosed into extruder
• Longer lifetime of screws and barrel.

The new design surpasses the performance of the larger L/D ratio extruders currently in today`s marketplace. This new screw design is also advantageous for applications like WPC extrusion as well as other difficult to plasticise materials.

Extruder	Max.output PVC Pipe kg/h
DS7.32	550
DS9.32	800
DS12.32	1400

High Performance NE40 Series for Polyolefin Pipe

A unique High Performance range of single screw extruders has been developed by Weber especially for HDPE and PP pipes. This range has 5 models with screw diameters between 50mm and 130mm. The lower energy consumption has rightly earned this machine range the label “WEBER GREEN TECHNOLOGY”

Advantages of High Performance NE40 Series machines:

• Long effective life of the grooved bush and processing unit through lower grooved bush pressure
• Constant outputs across the entire speed range
• Lower melt temperature compared to older machine concepts
• Output increase by upto 40% compared to older series
• Reduced energy consumption
• Reduced water cooling of the grooved feed bush and new drive concept
• Barrier screw with shear and mixing part
• Direct coupling motor – gearbox as an option
• Heat exchanger designed to divert the excess heat from the heater bands to any number of applications

Extruder	Max.output	Max.output
	PE-HD kg/h	PP kg/h
NE5.40	350	280
NE6.40	700	550
NE7.40	1100	800
NE9.40	1400	1000
NE12.40	2000	1450

Extrusion of PVC Foam Core Pipes

Multilayer pipes with compact PVC layers on the outer and inner walls and a centre layer produced from either virgin or recycled foamed material. Manufactured using the Weber FBL2 Feedblock, lightweight pipes with foamed core layer have been produced for non pressure applications especially used in waste water and sewer pipes (KG pipes).  

Extrusion of Corrugated Pipes and Double Wall Corrugated Pipes

 

In co-operation with renown manufacturers of corrugated pipe forming machines, Weber are able to offer suitable extruders for PVC, PE and PP corrugated and double wall corrugated pipes.

   

Advantages of Weber double wall corrugated pipe lines (co-extrusion):

• Low friction, floating suspension as a customised solution for balancing thermal expansion
• Optional screw removal from the back of the extruder for cleaning and inspection, meaning the injection head and corrugated pipehead does not need to be removed
• The entire extruder system is controlled by the Weber WPS3 control

Extruder for	Extruder for	Max.output
Corrugated Wall	Plain Inner Wall	PE-HD kg/h
NE6.40	NE5.40	850
NE7.40	NE6.40	1450
NE9.40	NE6.40	1700

 

Corrugated and Double Wall Corrugated PVC Pipes using the Weber FBL2 Feedblock

The core element of double wall corrugated PVC pipes is always the Weber feedblock. This feedblock has been used in industry for over 10 years. Constant optimisation and further development have made the current FBL2 better than ever with output capacities of upto 1,000kgs/hr and pipe diameters of upto 200mm extruded directly from the FBL2 without the need for an additional pipehead. Weber provides customers with individual advice regarding the suitable machine combinations.

Advantages of the Weber Feedblock:

• Very good wall thickness distribution
• High process reliability
• Minimum pipe weights achievable with high percentage of chalk
• Space saving extruder arrangements

PO Single and Double Wall Corrugated Pipes using the Weber PKM Pipe Head

Constant optimisation and further development have made the current PKM pipe head better than ever with pipe diameters from 20mm  upto 800mm.

Advantages of Weber PKM Pipe Heads

• Good wall thickness distribution through rheologically optimised flow channels
• High flow rate capacities
• Internal water cooling of the pipe reduces the sagging effect for pipes with thick walls
• Piped air cooling, cools from the inside and reduces the cooling path length
• Low shearing forces acting on the material

WEBER offer Extruders for all pipe applications

WEBER can offer complete Lines for PVC Solid Wall Pipes upto 630mm diameter (Including pipehead) with outputs upto 1,800 kgs/hr.

WEBER can offer complete Lines for PVC Foam Core Pipes upto 200mm diameter (including feedblock) with outputs upto 1,000kgs/hr.

WEBER can offer complete Lines for PE/PP Pipes upto 800mm diameter (including pipehead) with outputs upto 2,000 kgs/hr  with HDPE and1,450 kgs/hr with PP with their new “High Performance” extruders.

WEBER can offer complete lines for 3 layer and single & double wall corrugated pipe.

 

PEXa pipe extrusion line

A high quality pipe with exceptional properties. The peroxide cross linking of HDPE makes PEXa pipe one of the best of its kind.

Application:

Mainly for heating, sanitation pipes, in geothermal plants, for air-conditioning (area cooling), for gas installation, for offshore and industrial applications.

Infrared cross linking technology can be used to multiply the previously achieved output capacities of the ram process.

This economical manufacturing method lends new impetus to PEXa pipes.

Weber have developed a special processing technology for this method and can offer extruders and pipe heads with a capacity of upto 350kgs/hr and pipe diameters upto 160mm.

Crosslinking polyethylenes achieves a considerable increase in :- Creep strength, resistance to stress cracking, low temperature impact strength, long-term pressure resistance.  

Advantages of the Weber PEXa extruders

• High output capacities
• Maximum process reliability
• Good melting homogeneity at very low compound temperatures

WEBER co-extruders and WEBER double wall coating heads allow for the production of PEXa pipes with oxygen diffusion barriers.

WEBER offer both conical and parallel screw extruders for this application.