Benefits of using BorSafe HE3490-IM to produce Injection Moulded Fittings

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Julian Boone
5 years ago
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1 Benefits of using BorSafe HE3490-IM to produce Injection Moulded Fittings MEMBER OF

BorSafe HE3490-IM solves problems and reduces costs for fitting manufacturers BorSafe HE3490-IM is the first tailor made

Experience had shown that it was difficult to produce good quality injection moulded fittings at high productivity levels

BorSafe HE3490-IM was developed using advanced polymerization technology and a hexene comonomer and the material combines

The result is that good looking fittings can be produced with a reduced scrap rate and with increased productivity (lower

Examples of some of the improvements that fitting manufacturers have been able to achieve are shown in the opposite

BorSafe HE3490-IM has enabled fitting manufacturers to enhance their fitting product mix with new product developments.

growing PE100 gas pipe market in some regions.

good quality and processability to produce fittings of stable and accurate dimensioning.

2 BorSafe HE3490-IM solves problems and reduces costs for fitting manufacturers BorSafe HE3490-IM is the first tailor made PE100 material specifically designed for injection moulding pipe fittings. Experience had shown that it was difficult to produce good quality injection moulded fittings at high productivity levels using standard PE100 extrusion material and the problems got worse as the size of the fittings increased. BorSafe HE3490-IM was developed using advanced polymerization technology and a hexene comonomer and the material combines the strength of a PE100 material with dramatically improved flow characteristics. The result is that good looking fittings can be produced with a reduced scrap rate and with increased productivity (lower unit costs). Examples of some of the improvements that fitting manufacturers have been able to achieve are shown in the opposite pictures. BorSafe HE3490-IM has enabled fitting manufacturers to enhance their fitting product mix with new product developments. For example, there are successful developments of sophisticated electrofusion(ef) fittings up to 315mm to service the growing PE100 gas pipe market in some regions. The new EF fittings passed the stringent qualification testing for gas products, thanks to BorSafe HE3490-IM which provide good quality and processability to produce fittings of stable and accurate dimensioning. Another example is the successful development of heavy wall stub flanges without voids or warpage. Typical Fitting Cost Structure Fixed Cost Material Cost Savings in Costs Easier processing of BorSafe HE3490-IM means reduced costs, due to: Lower temperature injection less heating energy Lower internal stresses and warpage lower scrap rates Improved reproducibility of detail improved quality lower scrap Shorter cooling time/reduced cycle time lower unit cost Increased productivity lower stocks greater flexibility Greatly improved appearance of fittings improved saleability Process Cost

BorSafe HE3490-IM helps fitting producers solve problems around the world United Kingdom Reduced scrap rate The improved replication of BorSafe HE3490-IM on small fittings was also demonstrated on

Often fittings were rejected due to poor seating of the valve and brittleness of the spigot until they used BorSafe HE3490-IM.

3 BorSafe HE3490-IM helps fitting producers solve problems around the world United Kingdom Reduced scrap rate The improved replication of BorSafe HE3490-IM on small fittings was also demonstrated on Fusion s range of tapping saddles. This fitting contains an internal housing for an emergency flow stop valve which is activated if the house connection breaks and rapidly releases gas. Often fittings were rejected due to poor seating of the valve and brittleness of the spigot until they used BorSafe HE3490-IM. India Improved fitting appearance Sangir Plastics saw major improvements to the surface of their spigot fittings range when they used BorSafe HE3490-IM material. Sushil Mandhana said of the trials BorSafe HE3490-IM is a very good material for injection moulding, producing a uniform finish with no flow marks observed on the products, also the shrinkage is quite low compared to other PE100 materials.

China Reduced overall cycle time In trials at Zibo Jielin in Shandong, China on a 160mm electrofusion coupler they were able to reduce the injection temperature by 10 to 15 C.

Commenting afterwards on the trials Lu Guangjiong, Chief Engineer of Zibo Jielin said: Clearly the improved flow properties of the Borouge PE100 injection moulding material have a very positive

4 China Reduced overall cycle time In trials at Zibo Jielin in Shandong, China on a 160mm electrofusion coupler they were able to reduce the injection temperature by 10 to 15 C. This enabled them to reduce the overall production cycle time from 420 to 390 seconds and the surface appearance of the fittings was much improved and the ovality reduced from 1.0mm to 0.6mm. Commenting afterwards on the trials Lu Guangjiong, Chief Engineer of Zibo Jielin said: Clearly the improved flow properties of the Borouge PE100 injection moulding material have a very positive influence on both the quality and the productivity of the fitting tested. India Improved dimensional control Sprinkler irrigation couplers need to be tough and have an accurate external profile to match the metal quick release mechanism because they are regularly moved around the tea estates. Indian system manufacturers Rama Plastics, Nimbus Industries and Hall Mark Aqua all carried out trials with Borsafe HE3490-IM and found marked improvements in the quality and the dimensional accuracy of the fittings which makes them more attractive and easier to use.

Borouge PE 100 Grades BorSafe HE3490-IM This is a PE100 compound with improved flow properties, which makes it ideal for the production of injection moulded fittings.

BorSafe HE3490-LS This is a PE100 pressure pipe compound providing an excellent balance of production and end use properties.

5 Borouge PE 100 Grades BorSafe HE3490-IM This is a PE100 compound with improved flow properties, which makes it ideal for the production of injection moulded fittings. The higher flow enables a lower melt temperature to be used which reduces built in stresses (lower scrap rate) and the production cycle time (lower costs). BorSafe HE3490-LS This is a PE100 pressure pipe compound providing an excellent balance of production and end use properties. It is a high output material which has exceptional low sag properties but can be used equally well in smaller sizes, which means you only need one material in the silo. Borsafe HE3490-LS-H This PE100 pressure pipe compound has exceptional resistance to stress cracking making the pipe less vulnerable to failure due to installation damage. Ideal for the outer layer of a multilayer pipe installed using directional drilling or pipe bursting techniques. Commercial Reference Material Type Colour Application BorSafe HE3490-IM PE100 High flow Black Injection moulded fittings BorSafe HE3490-LS PE100 Low Sag Black Extrusion of pipes - all sizes BorSafe HE3490-LS-H PE100 HSCR Black High stress crack resistant for pipes for demanding installation conditions Some useful web sites and references Borouge Borealis PE100+ Association The Gulf Plastics Pipe Academy Water and Sanitation for the Urban Poor (WSUP) Water for the World Innovative PE100 material improves the quality and McGoldrick, J. et al, Plastic Pipes XIII, productivity of injection moulded fittings Washington, 2006 Development of a whole life costing model for large Shepherd, M. et al. Plastic Pipes XIII, diameter water mains Washington, 2006 Development of a New High Performance PE pressure Kania, G. pipe system, from design phase to reality. No Dig. Rome 2007 Special high quality PE100 pipe materials ensure long McGoldrick, J et al. service life and solve practical end-user problems. Wiesbadener Kunststoffrohrtage, 2007 The Use of High Stress Crack Resistant PE Pipes for Walton, D. & Murali, M. Demanding Installation Conditions SAPPMA Conference, A tough initiation for PE100 in Kuwait s oil industry Hayes, P., Plastic Pipes XV, Vancouver, 2010

6 About Borouge Borouge is a leading provider of innovative, value creating plastics solutions. A joint venture between the Abu Dhabi National Oil Company (ADNOC), one of the world s major oil and gas companies, and Austria based Borealis, a leading provider of chemical and innovative plastics solutions, Borouge is a groundbreaking international partnership at the forefront of the next generation of plastics innovation. Borouge has its headquarters in the United Arab Emirates and Singapore, employs approximately 1,600 people representing more than 40 nationalities and serves customers in more than 50 countries across the Middle East, Asia-Pacific, Indian sub-continent and Africa. Building on Borealis unique Borstar technology and experience in polyolefins for more than 50 years, Borouge provides innovative, value creating plastics solutions for the infrastructure (pipe systems, and power and communication cables), automotive and advanced packaging markets. In 2010 Borouge tripled its annual production capacity in Abu Dhabi to 2 million tonnes and an additional 2.5 million tonnes per year will be introduced by mid-2014 to create the world s largest integrated polyolefins plant. Borouge is also investing in plants and logistics hubs in Asia and an Innovation Centre in Abu Dhabi. Today Borouge and Borealis have a manufacturing capacity of over 5.4 million tonnes of polyethylene and polypropylene annually. Focused on Value Creation through Innovation they ensure that their customers throughout the value chain, around the world, can always rely on superior products and security of supply. Borouge is committed to the principles of Responsible Care and together with Borealis proactively contributes towards addressing the world s water and sanitation challenges through their Water for the World initiative. Visit and see how we are Shaping the Future with Plastics. Borouge PF BR 171 R GB BRG Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borouge extends no warranties and makes no representations as to the accuracy or completeness of the information contained herein, and assumes no responsibility regarding the consequences of its use or for any printing errors. Our products are intended for sale to industrial and commercial customers. It is the customer s responsibility to inspect and test our products in order to satisfy himself as to the suitability of the products for the customer s particular purpose. The customer is also responsible for the appropriate, safe and legal use, processing and handling of our products. Nothing herein shall constitute any warranty (express or implied, of merchantability, fitness for a particular purpose, compliance with performance indicators, conformity to samples or models, non-infringement or otherwise), nor is protection from any law or patent to be inferred. No statement herein shall be construed as an endorsement of any product or process. No one is authorised to make representations or give warranties or assume any other liabilities on behalf of Borouge except if in writing and signed by a duly authorised Borouge employee. Insofar as products supplied by Borouge are used in conjunction with third party materials, it is the responsibility of the customer to obtain all necessary information relating to the third party materials and ensure that Borouge products when used together with these materials are suitable for the customer s particular purpose. No liability can be accepted in respect of the use of Borouge products in conjunction with other materials. The information contained herein relates exclusively to our products when not used in conjunction with any third party materials. For more information contact: info@borouge.com or visit BorECO and Borsafe are trademarks of Borealis group. Borstar is a registered trademark of Borealis group. SALES & MARKETING Singapore (Head Office) Borouge Pte Ltd 1 George Street #18-01 Singapore Tel: Fax: info@borouge.com

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