Pipe products made from polyvinyl chloride have found wide application in many areas of modern life. The reason for its demand is the excellent quality of the products. How are PVC pipes produced, and what raw materials and equipment are used for this?
They are used when laying pipelines designed to move almost any media - gases, liquids and chemicals. PVC pipes and PVC connecting elements for them are used in the construction of residential buildings and industrial enterprises.
When constructing houses, plastic products are used for laying utilities, including external sections of highways - these are sewer and water supply networks, as well as drainage structures.
Such pipes are resistant to aggressive environments, they can be used in different temperature conditions, and they are easy to install. Pipelines laid from them have a long service life.
The raw material for the manufacture of PVC pipes is granular polymer. They are produced using the extrusion method.
In order to impart certain properties to pipe products, the following is added to the components:
In addition to the above additives, polymer raw materials sometimes include other components that affect the properties of the final product.
To organize the workflow, you will need equipment for the production of PVC pipes, including:
In addition to this equipment, depending on the type of products being manufactured, PVC pipe manufacturers may use additional mechanisms and devices, for example, a hydraulic stacker.
The process of producing PVC pipes is simple, it is not labor-intensive, does not consume energy and is environmentally friendly. All equipment necessary for organizing production can easily be placed in an area of no more than 100 square meters.
The extrusion production line operates in a continuous and complete cycle consisting of the following stages:
The technology for manufacturing products at the PVC pipe plant is as follows:
Pipe products made by extrusion can be used for arranging:
PVC pipes can perform a protective function when installing electrical wiring and communication cables.
Depending on the purpose, PVC pipe products can be non-pressure or pressure. In the first case, the pipes serve to move liquid through them by gravity, and in the second, the contents are supplied under pressure. Currently, the production of non-pressure PVC sewer pipes has become widespread.
The work of laying pipes made from PVC is simple and does not require the purchase of special equipment.
Installation is carried out in two ways:
When organizing the production of PVC pipes, the costs of purchasing equipment and other activities usually pay off within one year.
First you need to rent a small factory or part of an industrial premises outside the city. Mandatory conditions: good transport accessibility, convenient access roads, area of at least 200 sq.m. There must be 380 volt electricity, sewerage, and water supply.
It is important to provide several zones separated from each other:
Taking into account the fact that the pipe production line includes tall and heavy equipment, the ceiling height must be at least 10 m. Powerful air conditioners and fire protection systems must be installed in the workshop. The storage area should have normal humidity and room temperature.
When organizing a line of standard size and configuration, it is necessary to hire about six workers. This is necessary to ensure uninterrupted production (three employees per shift).
Additionally, it is necessary to hire an accountant, auxiliary workers, a process engineer, and two machine operators. Thus, the list of monthly expenses will need to include $6,000 as employee salaries.
Since the business of manufacturing HDPE pipes belongs to the category of technically complex industries, at the stages of its organization you will need to obtain permission from the local administration, the Sanitary and Epidemiological Station, the State Energy Supervision Authority, and the fire inspectorate. As for registration, the optimal form is LLC.
You can purchase both new and used equipment of domestic or foreign production. When purchasing a Russian-made line, you can save some money.
List of required line components:
Products for the manufacture of HDPE pipes are selected individually. High-quality raw materials are polymers of different pressures, polypropylene, polyvinyl chloride,.
Raw materials should be ordered from trusted suppliers. The highest quality and most reliable brands are Hastalen 5416 (Bazell), Vestalen 9412 (SABIC), imported.
The pipe manufacturing process is based on the extrusion method. The essence lies in the homogenization of raw materials in order to soften them in a special device - an extruder. With the help of equipment dies, pipes are formed to a specified diameter and then cooled.
In the first step, the material is placed into the extruder receiving device. Next, the raw material is moved into a preheated cylinder. Gradually, the material is transferred to the hottest parts of the cylinder, slowly warming up.
Thus, the cylinder consists of three components: a feeder, a raw material compression zone, and a dispensing zone. The high quality of the extruder die is important, since the size of the finished pipes depends on it. It must be maintained at a fixed temperature.
After the raw materials pass through the cylinder and the blanks are obtained, they are placed in a container for vacuum molding under pressure. The pipes are then removed from the cooling chamber and immediately transferred to the conveyor to prevent its deformation.
At the final stage, the pipes are cut and laid into prepared coils. For cutting, special saws or cutters are used (depending on the selected diameter).
In order to launch the production of HDPE pipes, at least $140 thousand will be required. This includes the cost of monthly rent, wages, repairs of rented premises, purchase of equipment and raw materials.
The price of a finished product unit depends on its type. In this case, the rule applies: the larger the diameter, the more expensive the product.
With full sales of products, monthly income can be up to $6,000. The investment pays off in about 2 years.
Polyethylene is serious business. It requires not only large financial investments, but also professional knowledge in the field of production and experience in managing a large organization.
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PVC pipes are pioneers among polymer pipes, which began their journey more than half a century ago in America and Europe. In the domestic market, PVC pipes gained popularity extremely slowly. This is explained both by the conservatism of the consumer and the lack of a full-fledged regulatory framework that allows the widespread use of PVC pipes in housing and communal services.
Slowly but surely, pipes made from polymers of this group are constantly expanding their sector in the pipe products market due to the improvement of the quality characteristics of pipelines. This is achieved thanks to the emergence of not only innovative technologies for the production of PVC pipes, but also new methods of installing pipeline networks.
The raw material for the production of PVC pipes is granulated PVC polymer.
To create a full range of required properties, a number of additives are used in the manufacture of these products:
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Other components can be added to the standard composition to impart certain properties to the product. Supplements, as a rule, are manufactured abroad.
An extrusion line for the production of PVC pipes provides a continuous cycle consisting of the stages of extrusion (pushing the material through the molding hole), calibration and cooling in baths, drawing, cutting the pipe to a given length and laying the finished product.
The extrusion line includes:
The extrusion head can have a design solution in the form of a single block with a flange for fixation to the material cylinder. Consists of the following elements: body, matrix, divider, mandrel holder.
The matrix is centered relative to the position of the mandrel using adjusting bolts. The uniformity of the diameter of the pipe wall thickness depends on the accuracy of alignment.
The German company Krauss Maffei specializes in the production of high-performance extrusion lines for the production of pressure and non-pressure PVC pipes. The largest plant for the production of PVC pipes in Russia, JSC Hemkor, uses several such lines. The quality of the plant's products has increased thanks to the introduction of a gravimetric dosing system for raw polymer.
The process of producing pipes from polymers is relatively simple, environmentally friendly, and requires little labor and electrical energy. The area required to install and operate a complete line for the production of polymer pipes is only about 100m2.
The production of PVC pipes begins with pouring granular polymer into a hopper 
extruder. In the extruder, a screw made of high-quality nitrided steel rotating inside a material cylinder mixes the incoming granules. During rotation, the material is heated to a predetermined temperature.
The molten polymer is fed into the extrusion head, where the forming elements of the cylindrical surfaces are:
At the exit from the extrusion head, a plasticized blank in the form of a pipe is obtained. To give the pipe blank the required outer and inner diameters, ensuring uniform wall thickness along the diameter, it is calibrated in a vacuum calibrator (bath).
The calibrator is a stainless steel container three meters long, at the ends of which rubber cuffs are installed to ensure tightness.
The outer diameter calibration device is located at the front of the bath and is a stainless steel cylinder with a central hole whose diameter is equal to the diameter of the pipe. Through the diaphragm of the calibrating device, the pipe enters the cooling bath, in which a vacuum is also maintained.
To stretch the pipe evenly, tracked or belt-type pulling devices are used. Pipe cutting is carried out with circular saws or guillotine shears. At the end of the line there are devices for laying products on a special rack or for winding small-diameter pipes. These devices can operate in both manual and automatic modes.
The production of PVC sewer pipes, which belong to the non-pressure category, can be focused on the production of pipes with a single-layer wall (monolithic pipes) or with a three-layer wall.
The outer layers of a three-layer pipe are made of virgin uPVC. The intermediate layer has a porous structure, and is made from either our own recycled uPVC or a third-party recycled polymer.
Process Innovation
One of the innovations in the production of PVC pipes is the production of biaxially oriented pipes. These products have high impact strength and other mechanical characteristics while simultaneously reducing wall thickness, pipe weight, and, consequently, its cost.
Since the production of PVC pipes is not a very complicated and labor-intensive process, and the demand for such products is constantly increasing, this direction is promising for those who want to organize their own business. The payback time for the investment depends on the level of equipment utilization. At 50% utilization of the extrusion line, the costs are recouped in about a year.
Over the past few years, the production of plastic pipes has significantly improved and expanded in scale. More and more companies are opening their own workshops for the production of these products.
The popularity of plastic pipe production is due to their widespread use. After all, these products are used for the construction of sewerage, heating systems, gas and water supply. This is not a complete list of all possible applications of plastic pipes.
Due to such popularity of products on the Russian market, there is considerable competition among manufacturers. Therefore, manufacturing technology is constantly being improved. And in order to beat competitors, it is necessary to produce high-quality products at an attractive price for customers.
The manufacturing technology of plastic pipes is simple and does not require careful study. But before we consider it, let's discuss the advantages of this product. Firstly, plastic pipes have a durable composition that will never rust or rot. The maximum withstand temperature reaches +170 degrees C. Unlike metal, there are no lime deposits on plastic.
The shelf life with proper use is approximately 50 years. As you can see, there are many advantages. But let's get back to manufacturing. The production of plastic pipes is based on so-called extrusion. That is, the product itself is created by extrusion from molten raw materials. Production begins with the raw material being poured into the extruder receiver hopper, where the material is melted using high temperature.
After which the resulting mass enters the forming sector. There, the future parameters of the pipe are determined. Next, the product is cooled in a special bath. The calibrating mold completes the design formation stage. At the very last moment, the finished pipes are cut and laid.
The necessary equipment for the production of plastic pipes depends on the type of production required. One of the main devices is an extruder. It comes in several types, namely: screwless, screw and combined. The process of an extruder can be compared to a juicer. When the raw material enters it, it is completely crushed (melted).
The screwless device is equipped with a disk, where the main part of the work takes place. This type of extruder can process mixed materials. But, as statistics show, such an opportunity is useless in production. Therefore, screw extruders are most often used.
The full production cycle additionally requires the use of certain devices, such as a transport belt, a raw material supply system, a mixer, a pulling apparatus, a vacuum molder and storage tank, baths for calibrating and cooling the laying pipe, and a pipe cutting machine.
Each of these devices has its own personal performance indicators, which determine the speed of operation. The cost of a complete set of devices varies greatly depending on the exact characteristics of the individual devices. According to the latest data, all equipment for the production of plastic pipes costs 400 thousand rubles (this is the lowest price).
The production of plastic pipes can occur using various types of raw materials. The most commonly used polymers (both high and low pressure), polybutene, polypropylene, polyvinyl chloride, etc. The choice of raw materials depends on the chosen type of production. When selecting materials, it is important to pay attention to quality and shelf life.
This is especially true for polymers. Polypropylene, as well as polyethylene, have a long shelf life (which is what attracts most manufacturers). The cost of raw materials depends on the quality and type. For example, polypropylene costs 50-70 rubles per kg. Polyethylene is a cheaper raw material - 32 rubles per kg. As a rule, at the stage of purchasing equipment, the main type of materials used should already be selected.
There are no special requirements for choosing a room. The main thing is that the machine for the production of plastic pipes and other necessary equipment fit. Of course, do not forget about a special room for working personnel. The building must also have a bathroom and storage area. It is prohibited to build such factories in the city. It is necessary to organize convenient entry for trucks. Depending on the amount of equipment, the building area should be from 40 to 200 square meters.
A plastic pipe production line must be operated by at least three workers. The list of personnel includes a technologist, an operator and an assistant. If workers have never encountered such equipment, they need to be given precise instructions on all machines. At first, you may need to control everything yourself.
As a rule, a technologist receives 50 thousand rubles, an operator – 25-30 thousand rubles. But depending on the load and location, the numbers will change. Also, do not forget that you will need to hire several work groups who will work in shifts. Each of them must appoint its own leader. This will make it easier for you to manage your staff.
The production of plastic pipes requires permission from a number of government agencies. If you have additional funds, you can use the services of specialized companies that help in collecting the necessary documents. Permission must be obtained from Gosnadzorohrantruda, fire inspection, gas service, sanitary and epidemiological station, local executive authorities.
In addition to the documents, there are a number of rules for transporting and storing plastic products. The conditions are established in accordance with GOST 18599-2001. Transporting finished products is permitted only in closed transport. The pipes themselves must be completely placed in protective packaging and equipped with plugs. During transportation, it is not allowed to transport pipes longer than 5.5 meters and weighing more than 1.25 tons (including packaging).
The article will discuss the specifics of manufacturing plastic pipes, the necessary equipment and raw materials. A separate paragraph will describe the production technology.
Currently, the country is experiencing an expansion in the production of plastic pipes. This is due to the ease of manufacture and the high demand for this type of product. Plastic pipes are in demand when laying sewerage systems, water and gas supply systems, heating, and installation of “warm floor” systems.
This is due to their operational properties, in particular:
The following can be used as a basis for the manufacture of plastic products: polymers of various pressures, polybutylene, polypropylene and similar raw materials.
A machine for the production of plastic pipes is an extruder that forces the product through molten plastic through a forming hole.
Extruders are divided into three subtypes:
Let's move on to listing the equipment for the production of plastic pipes. As mentioned earlier, an extruder is needed to set up the process. But that's not all that's needed.
Necessary equipment:
Typically, granular polymers are purchased for production. Particular care must be taken to monitor their expiration date and quality. Polypropylene and polyethylene perform especially well. They have the longest shelf life, so these materials are considered the most profitable.
Polypropylene copolymer is also in high demand for pipe production. This is due to the low price per kilogram. And the most inexpensive raw material is low-density polyethylene.
An important nuance: when starting this type of business, it is preferable to always purchase from one plant, because when the raw materials used change, you will need different equipment for the production of pipes. And this state of affairs will be associated with various types of losses.
As has already become clear, the method of making plastic pipes is based on the extrusion method. This is a closed cyclical process. Let's study its nuances in detail, using polyethylene products as an example.
According to the technology for the production of plastic pipes, the raw materials are polyethylene PE-80 and PE-100, which contains special additives. With their help, the material is given the properties necessary for subsequent use.
The production of plastic pipes itself consists of 9 successive stages. It is very important to monitor the quality of the process at each of them.
Production stages:
After the pipes are manufactured, they should be sent to the quality control department, where the geometric dimensions of the products will be checked.
In particular, the following parameters are measured:
Laboratory staff, acting in accordance with the regulations, will select samples from the received batch for testing. If the studied parameters are normal, then a quality compliance document is attached to the batch. They are then sent to the customer.
Particular attention should be paid to the quality of manufactured products. Coordinated and extremely precise functioning of all elements of the technological process is required. This is the only way to deliver high-quality products to the consumer in accordance with the order. If things go differently, the business will not be successful and its owner will suffer losses.
If we summarize all of the above, it becomes clear that the process of manufacturing plastic pipes is distinguished by thoughtfulness and automation. It does not require significant expenditure of either resources or time. Among other things, production produces virtually no waste and has no negative impact on the environment. And the production line can be placed in a relatively small room; its area will take up less than 100 square meters.
