What is a PVC Pipe?
PVC pipes are made out of a material known as polyvinyl chloride, a durable, strong plastic-like substance. Pipes are constructed from this material and used in various applications from plumbing to construction. The pipe is designed to be universal. All pipes are designed around specific requirements to ensure that multiple pipe sections will t together. The ends of the pipe can either be smooth or grooved (similar to a screw). Additionally, there are several different pipe sizes ranging from very small (one-fourth inch) to very large (10 feet).
What is PVC Pipe Used For?
PVC pipes are commonly used for manufacturing sewage pipes, water mains, and irrigation. Possessing very long-lasting properties, PVC pipes are easy to install, lightweight, strong, durable, and easily recyclable, making them cost-efficient and sustainable. The smooth surface of PVC pipes also encourages faster water flow due to lower amounts of friction than piping made from other materials such as cast iron or concrete.
How are PVC Pipes Made?
PVC pipes are manufactured by extrusion of raw material PVC, and generally follow the same steps of typical pipe extrusion operations:
- Feeding of raw material pellets/powder into the PVC twin screw extruder
- Melting and heating in multiple extruder zones
- Extruding through a die to shape into a pipe
- Cooling of the shaped pipe
- Cutting of PVC pipes to the desired length.
However, despite having a similar manufacturing procedure to most plastic piping, PVC pipes have intrinsic characteristics that pose additional challenges to pipe manufacturers both in terms of production, as well as positioning their products on the market.
The Challenges of PVC Pipe Manufacturing
Increased Extruder Friction
Due to the nature of PVC plastic, PVC extruders are subjected to high amounts of friction and stress. This means that to guarantee a long service life, PVC pipe production lines require the use of specialized extruders that utilize a twin-screw extruder configuration, as well as featuring robust construction materials that can withstand the harsh PVC extruder operating conditions.
Differentiating From Competitors
Because PVC piping is one of the most used types of piping, there is a lot of competition between manufacturers. It is therefore of paramount importance for PVC pipe producers to differentiate themselves from their competitors, both in terms of delivering consistent product quality, as well as offering a wide range of products at competitive prices. Such differentiation can only be achieved through the use of world-class manufacturing equipment, that maximizes productivity while minimizing costs and has the capacity to produce a wide variety of PVC pipe sizes. DRTS offers a range of effective turnkey solutions that guarantee this type of effective operation, such as equipment with integrated Industry 4.0 functionality, advanced connectivity, ease of integration and multilayer die heads that maximize savings.
Providing A Comprehensive Product Range
PVC pipes come in various sizes and diameters, and for each size exists a variety of things. Therefore it is highly desirable for PVC pipe manufacturers to present the market with a comprehensive range of products. DRTS supports PVC pipe producers with a wide variety of ready-made PVC pipe things, available in various types and sizes, helping you bring your products to market with a complete family of PVC piping products.
Calcium carbonate for PVC Pipe making
PVC pipe compounds typically contain varying amounts and types of calcium carbonates, paraffin waxes, and other ingredients such as stabilizers, titanium dioxide, calcium stearate, and processing aids. the effect of calcium carbonate particle size, coating, and usage level on the properties of PVC pipe depends on the quality of Calcium carbonate (purity, whiteness, hardness, particle size,…) Calcite is a filler, allowing to harden the plastic through the formation of a composite, and allowing to use less plastic, which is an expensive ingredient. In other words, putting calcite in the plastic leads to a cheaper material having a higher elastic modulus. Sand may have the same role and is even harder. So what is required is a material which is cheap, and whose modulus is higher than that of plastic. The grain size should be compatible with the process. A broad distribution of sizes will make the filler packing more compact.