For winding pipe technology

For winding pipe technology

Machinery for a Japanese customer, type PROFILLINE P - 2100 2

PROFILLINE The innovation Founded in the year 1956, bauku is the most experienced producer for profiled plastic pipes worldwide. From the very beginning, bauku was using the own machinery technology to produce and to sell plastic pipe systems for the German Market. It is our philosophy to design a high quality plastic pipe product for the customer first, before we think to design the right machine for the application. As a result, part of our patents are related to the product, part of the patents are related to the machinery equipment. Up to now we created more than 30 patents, proving that we are number one in innovation for the winded extrusion pipe. The diameter range of our machines starts at 300 mm and ends at 3500 mm inner diameter. Besides machines to fabricate the profile pipe for high ring stiffness, we can also supply extrusion lines for high inside pressure applications or for fittings for pressure pipes or high ring stiffness pipes. Since we sold our first machine to a foreign customer in 1972, we delivered more than 35 lines to the full satisfaction of our partners.

Pipe systems for high external loads and low inside pressure are produced with a profile. The profile construction offers a high strength combined with a relatively low weight of the product. The PROFILLINE P- series is extruding a pipe including the pipe joint (spigot and socket). The standard length of the pipes is 6 m. Of course also pipes for the fitting and manhole fabrication are standard for this machinery concept. Depending on the product and application, the line is able to use three different basic profiles with the unique bauku twin head technology. A solid wall square profile is possible, a round shaped hollow profile and a combination of both profiles, without changing a single part at the die head. This offers the customer a maximum flexibility for an economical production. 4

P-Series mandrel pipe dismantling station carriage rails extruder winding station HDPE resins are also suitable for this kind of extrusion process, but are old fashioned. Production method The solid wall profile is useful for fittings like bends, the square profile with a smooth inside and outside surface of the pipe is ideal for manholes, whereas the omega profile is the best choice for the pipe. The profile has an inner core tube made from PP, which is stabilizing the form during the extrusion process. Our first choice for extrusion is PP, giving an extraordinary e-modulus and strength, combined with a high chemical and temperature resistance, a high flexibility and a low profile weight. The profile is extruded with 200 C and is guided directly onto the surface of a steel mandrel. The mandrel is turning around at winding stations and the extruder passes the station on a rail system. These movements result in a spiral winding process, where the profiles are overlapping and melting, as the material still has 200 C. Once the extrusion for a 6 m pipe is finished, the product is cooling down, while the extruder is starting at the next winding station. After the cooling process, the mandrel is folded down and extracted from the pipe, then folded up again and is returning to the winding station for the next production sequence.

6 Pipe systems for low external loads and high inside pressure are produced with a solid wall, if necessary in addition with a glass fiber layer inside. The solid construction offers a high strength against tensile stresses in the pipe wall. The PROFILLINE S-series is extruding a pipe with plain pipe ends. The standard length of the pipes is 6 m. Of course also pipes for the fitting and manhole fabrication are standard for this machinery concept. Depending on the product and application, the line is able to use three different materials in one die head. The HDPE 100 is standard for high pressure pipes and is normally delivered in black color. A special colored material (for example light blue) can be added for the inside layer of the pipe and a glass fiber strip may be added in the die head for a higher pressure class.

S-Series Production method The steel mandrel is heated up on a heating station to reach a 160 C surface temperature, before the tool is moved onto the winding carriage to be placed in front of the extruder. The solid wall profile is extruded with 200 C and is guided directly onto the surface of a steel mandrel. The mandrel is turning around at a winding station and the station passes the extruder on a rail system. These movements result in a spiral winding process, where the profiles are overlapping and melting, as the material still has 200 C. Once the extrusion for a 6 m pipe is finished, the pipe with the mandrel is moved to a cooling station. The next pre-heated mandrel is taken form the heating station onto the carriage and the production sequence starts again. Optional For an easy welding of the pipes later on the job site, a product made from HDPE only is the best choice. In case the glass fiber is added, a special end design of the pipes is provided by the machine, in order to keep away the fiber from the welding area. Using just HDPE 100, the 10 bar pressure rate is limited up to a diameter of 2400 mm. Adding the fiber, the 10 bar will reach its limit at diameter 3000. In case a colored inside layer is part of the product, an additional small extruder will supply this material into the main die head of the main extruder. In case the glass fiber is also part of the equipment, this material will be fed into the main die head as well, however just for the middle layers, so that this material will never touch the inside or outside surface of the product.

8 The diameter range of axial extruded pipes is getting bigger and bigger every year. An outside diameter up to 1600 mm is sometimes available in different markets. Besides the fact that a machinery like this asks for a mass production of just one diameter, which is the harder the bigger the diameter range gets, these machinery lines just offer the pipe, but no fitting at all. For smaller diameters up to OD 630 fittings like flanges and stub ends maybe produced by injection molding, however bigger fittings have to be machined by hand, creating a high percentage of waste and labor work. The PROFILLINE F-series is the answer to this market needs, as it is designed and optimized to produce all kind of fittings.

F-Series crane system double winding station rails extruder carriage Production method The basic winding process is familiar to the one described for the S-series, but the F-series is just using mandrels with a length of 2 m. On the other hand, four of these mandrels can be put into operation without a change of tools, creating a high speed process for fittings. The mandrels are folded on the stations and the fittings are dismantled automatically, making the process easy to control. Even mandrels for round shaped fittings like manhole bottoms and covers can be supplied.

The success When bauku started not only to produce plastic pipe systems, but also to develop and to produce machinery lines for the unique profile extrusion process in 1972, this was the beginning of a successful story. In many countries all over the world there was a serious interest in the high quality products, as the environmental problems were similar to the ones in Germany. From the very beginning bauku decided to enter the foreign markets step by step choosing the customers for the machinery lines very carefully. The aim was not selling as much extrusion lines as possible, but having long term relationships with partners transferring the necessary knowhow for both, production technology and product technology. 10

PROFILLINE Canada France Norway England Germany Italy Serbia Iran VAE India South Korea USA Japan Mexico China Malaysia Trinidad Australia Today the profiled plastic pipes invented by bauku is available in many countries all over the world, even so the company name and the brand name of the product may be different. Our customers are selling the pipe systems as spiral, black brute, performance pipe or using other brand names, however it is always the bauku technology and quality that is behind the scenes. We meet potential customers at the trade fair IFAT in Munich or the K in Düsseldorf, Germany, but we also attend on trade fairs in foreign countries from time to time. A full range of products, services and know-how is available and makes it worth to discover the bauku world.

Hawerkamp Maschinenbau und Kunststoffrohr GmbH Industriegelaende 7, 51674 Wiehl, Germany +49(0)2262-7889775 info@bauku.com www.bauku.com www.facebook.com/bauku.extrusion Hawerkamp Maschinenbau Member of the Hawle Deutschland Beteiligung GmbH bauku, 02.2018