The flexible uniEX 45-30 single-screw extruder – ideal for processing pipes and profiles in the medium-output range (photo: battenfeld-cincinnati)

With this new machine series, battenfeld-cincinnati systematically continues its product development strategy. After the twinEX twin-screw extruder series and the solEX single-screw extruder series for high-speed applications, the uniEX has now also become an integral part of the extrusion specialist’s product range. This at-tractive standard series with a 30 D processing length has been developed on the basis of the proven machine series from the bat-tenfeld-cincinnati group of companies. It has been optimized on the basis of some 3,000 extruders installed worldwide and numerous proven screw geometries. A choice of extruders with screw diameters of 35, 45, 60 and 75 mm is available.

The processing highlight of the new extruders is their consistently high specific throughput at every screw speed. This is due to the extruders‘ special feed zone. An additional benefit of the machines from the uniEX series is the extremely wide process window, as well as the option of processing a great variety of materials thanks to specialized screw geometries. The well-coordinated extruder concept favors high throughput at low melt temperatures and con-sequently high process stability.

The flexible uniEX 45-30 single-screw extruder – ideal for processing pipes and profiles in the medium-output range (photo: battenfeld-cincinnati)

The processing units are mounted on an extremely robust basic frame in a space-saving U configuration. Thanks to their powerful drive system, uniEX extruders are laid out for handling melt pres-sures of up to 500 bar, while maintenance-free AC motors keep energy consumption low.

An absolute novelty are the uniform control cabinets and control units used for the first time in this series. The latter are not only extremely easy to operate, but also offer the option of having sev-eral extruders of a coextrusion line integrated in a single control system if desired.

source: www.battenfeld-cincinnati.com

The deal, at a value of €11.9 million, leads to an impairment write-down of €10.5 million for the financial year 2011, impacting the operating profit of continuing operations. For this reason, Uponor’s full-year operating profit for 2011 will remain clearly below the previous year’s level.
In 2011, Hewing GmbH generated net sales of nearly €50 million, and employed a staff of 230 persons. Operating under its own brand name, Hewing has served as an OEM pipe manufacturer to various central European underfloor heating and plumbing system brands. Hewing’s PEXc pipe technology has been non-core for Uponor after the global brand realignment in 2006, resulting in a stronger focus on the Uponor multi-layer composite and PEXa pipe technologies in building solutions.

Uponor’s CEO Jyri Luomakoski comments on the deal:

• The business environment for OEM manufacturing has weakened in Europe in recent years, and the evolution was speeded up by the difficult market conditions in the past few years. This has severely impacted performance, with little room for improvement in the current setup.
• We are happy to have found a buyer who can bring a considerable own volume to Hewing. I believe this is a favourable move for the entire industry that is faced with idle capacity especially in central Europe. I trust the deal will bring optimism about the future amongst the personnel of Hewing.
• The deteriorating performance of Hewing in the recent years has had a notable impact on Uponor’s consolidated results. In addition to operating profit, the divestment will have a positive impact on our future cash flow from operations and gearing.

The deal is effective 1 January 2012, pending on certain factors, such as an approval from competition authorities. The closing of the deal is expected to take place in March-April 2012.

Uponor will continue to have a presence in the Ochtrup region where it has some warehousing, administration and marketing services related to the PEXa technology-based business under the Uponor brand.
Uponor acquired Hewing GmbH in early 1988 as its first step in the strategy to enter the growing market of hot water pipe systems for buildings. Hewing’s advanced know-how of cross-linked polyethylene pipe (PEXc) technology and its access to new customer segments in Germany have played a key role in Uponor’s journey towards its leading international position as a supplier of building solutions in Europe and North America.

source: www.uponor.com

European product standards for technical insulation materials

With its Armaflex products Armacell is the first manufacturer to offer CE-certified flexible technical insulation(photo: Armacell GmbH)

From August 2012, only technical insulation products which comply with the European product standards and bear the CE mark may be sold in Europe. A mandatory frame-work will then apply for the key product features of technical insulation materials – such as thermal conductivity, resistance to water vapour transmission, fire behaviour, toler¬ances etc. The transparency achieved will allow specifiers, distributors and installers to make a quick and direct comparison between the products on offer. The European product standards provide greater legal certainty in the specification and installation of technical insulation materials and the CE mark will have a positive impact on pan-European trade.

European fire classification

One important change is that the national fire classifications which have applied so far, such as the German B1 and B2 fire classes or the Spanish M1, will be replaced by standardized European fire classes. The new classification uses the seven fire classes A to F which are already valid for other construction products. For pipe insulation a subscripted ‘L’ (for ‘linear products’) will be added. Another new feature is the informa¬tion on smoke development and burning droplets, which will be marked with ‘s’ and ‘d’ respectively.  In the European fire test, the majority of the Armaflex products achieve the class B/BL-s3 d0, the best possible fire class for elastomeric insulation materials.

First technical insulation materials with CE mark

The product designation code on the carton provides information on the key properties of the product(photo: Armacell GmbH)

As the first manufacturer of technical insulation mate¬rials on the basis of synthetic rubber Armacell now already provides CE-certified products. The insulation plant in Münster, the largest Armaflex production facilities worldwide, was successfully certified at the beginning of November; further European factories are currently under¬going the conformity assessment procedure. The CE mark and the product designation code, which provides information on the key product properties, can be found on the product cartons.

Armacell and its predecessor Armstrong Insulation Products played a significant role in the European work on standardization for technical insulation materials and were one of the parties steering the process from the mid eighties. As the developer of Armaflex, the first flexible pipe insula¬tion made of elastomeric foam (FEF), the company founded a completely new branch of industry in the mid fifties. Armacell is therefore particularly committed to shaping the process of European harmonization in this sector of industry responsibly.

source: www.armacell.com

photo: PCT Ltd

Low Ovality Technology not only reduces transport costs by maximising the amount of coiled pipe per load but also greatly increases the integrity of the finished pipeline. For example, DN160 pipe can be coiled in 900m lengths allowing for a much quicker installation time, by removing up to 73 butt welds per 900m coil, and with less joints the pipeline’s integrity is significantly increased. For larger projects, 4600m of DN160 can be put on a reel increasing the efficiency of modern ploughing technologies. With new ploughing technologies and the need for longer continuous lengths and larger diameters in coil form, Low Ovality is well positioned to remove the constraints of butt welding backlogs and joint failures during the installation and life time of the pipeline. Reels of this size would require an escort on highways, however, the cost savings made through a much more efficient installation process far outweigh the additional transportation costs and with fewer joints, maintenance costs of the pipeline are also considerably reduced.
Even with pipe sizes that can already be coiled with standard coiling machinery, Low Ovality can make a big difference to profit margins through its ability to supply longer lengths of coil within existing coil dimensions, increasing the pipe length per truck and so reducing overall transportation costs. Transporting thinner walled pipes in coil format also becomes a possibility with Low Ovality as it is capable of coiling pipes with SDR up to 21 & 26 whilst maintaining coil and pipe stability.

PCT Ltd is a privately owned company based in Newcastle UK with subsidiaries in the USA and China. The company designs and supplies coiling, handling and packaging solutions for flexible products such as plastic pipe, sub-sea umbilical, power cables, flow-lines and steel wire rope.

source: www.pipecoil.co.uk

KWD-globalpipe, 08.12.2011. In the current report, we are detailing “how many million meters of pipes have been used in the following applications: floor- or surface heating&cooling, radiator connection and sanitary systems. If we take Europe, most pipes for hot water installations hav e been sold in Germany. In the second place is Italy, followed by GB/Ireland and Poland.

If we now have a look by material:

• GB has marketed the largest quantity of copper pipes in Europe with approximately 100 million meters.
• Germany has marketed the largest quantity of PEX pipes in Europe with approximately 70 million meters as well as the largest quantity of PE-RT pipes with approximately 54 million metres.
• Regarding multi layer pipes (PEX or PE-RT with aluminium), German has sold the most, but Italy is a very close second.

European heating&plumbing pipe trends

The combined European pipe market had shrunk in 2009 by 10 % and in 2010 by a further 8 %. For 2011, the trend has reversed and turned positive again. Our research shows, that the European growth of pipes for hot water installations will be 1% in 2011 and around 3 % each year for 2012 till 2014.

It is a fact, that the political and economic development has never been quite as unpredictable as it is today. With this uncertainty in mind, and based on the numbers available, trends have been developed that are based on assumptions on how the housing market in each country will move, on what the expectations of the global players in the pipe market are and what the predictions of the councils of economic experts foresee.

To have a look on trends in pipe material, it can be seen that multi layer pipes are still increasing. But PEX pipes and, above all, PE-RT pipes show a continuously high rate of growth. The market share of PE-RT pipes for all applications reached in 2008 6,5 %. In 2010 it was already 8%, and we expect that it will be 9,6% in 2014. But if we only have a look on floorheating / surface heating&cooling, the market share for PE-RT pipes for this specific application grew from 27% in 2008 to 30% in 2010 and we expect it to be 33% in 2014. To compare, the market share of PEX pipes in the same application have been 48% in 2010 while multi layer pipes only have a market share of 14 %.

more Information | Orderform | KWD-Shop

Contact: KWD-globalpipe, Dipl.-Ing. Jutta Hix, hix@kwd-online.de, www.kwd-globalpipe.de.

Photo: KraussMaffei

KraussMaffei Berstorff and Crosslink Finland Oy, a manufacturer of infrared crosslinking ovens based in Tampere (Finland) and a source of expertise with many years of experience in the crosslinking of polyethylene pipes, have signed a cooperation agreement. Through this exclusive cooperation, two innovative and leading suppliers in the field of Extrusion Technology for hot water pipes are pooling their competencies in order to develop and jointly market complete systems for the extrusion of peroxide crosslinked polyethylene pipes.

“I am delighted that we have found a cooperation partner in Crosslink Finland Oy. In our opinion, the company is the most competent and most innovative partner in the area of polyethylene pipe crosslinking. Thanks to this cooperation, we will be able in future to offer our customers tailor-made solutions regarding the production of PE-Xa pipes since all system components can be perfectly matched to one another. We will therefore attain perfect quality during the production process“, said Dr. Hans Ulrich Golz, Managing Director of KraussMaffei Berstorff.

High-performance extruders from KraussMaffei Berstorff
KraussMaffei Berstorff has developed a special system technology for the production of PE-Xa pipes. The complete line from the twin-screw extruder with a conical processing unit and the pipe head through to the calibration and cooling system is perfectly matched to processing of a ready-mixed compound. The premixed compound consists of polyethylene, a stabilizer and peroxide. After these three components have been mixed, a diffusion process takes place: the liquid peroxide is absorbed by the granulated polyethylene. This produces an extremely homogeneous material mixture since the peroxide then not only lies on the outer layer of a single PE grain, but is also homogeneously distributed inside the grain. The system also ensures extremely reliable and constant process conditions, i.e. perfect product quality with a consistently high degree of crosslinking.

Crosslinking oven from Crosslink Finland Oy
The actual crosslinking of the PE pipe takes place in the infrared crosslinking oven, which is supplied by the partner Crosslink Finland Oy and is integrated in the overall system concept. “I am proud to be able to cooperate with KraussMaffei Berstorff, one of the leading international extrusion system manufacturers“, enthused Aarne Heino, Managing Director of Crosslink Finland Oy. Heino is looking to the future with optimism: “I am anticipating much more interest in PE-Xa pipe extrusion and especially in our solution.” “We are also focusing on a long-term partnership with Crosslink regarding further development in the areas of higher production speeds, larger pipe diameters and multi-layer pipes“, emphasized Dr. Golz.

Effective crosslinking process using the inline method
In the PE-Xa pipe extrusion concept, the crosslinking process takes place inline, i.e. the PE pipe is also crosslinked with the molding process by means of infrared rays; consequently, there is no need for another downstream production step which is absolutely essential with other crosslinking methods. The manufacturer profits from drastically reduced costs for working hours, space requirements, handling and transportation.

Peroxide crosslinked pipes in numerous application areas
Peroxide crosslinked pipes are characterized by different product properties, for example high flexibility and great resistance to heat and cracking. They are used in panel and radiator heating systems, as well as in the supply of hot water, drinking water and gas. PE-Xa pipes are also being used to an increasing extent for alternative laying methods.

Source: www.kraussmaffei.com

battenfeld-cincinnati single-screw extruder with torque motor (Photo: battenfeld-cincinnati)

In pipe, profile, sheet and film extrusion, the energy costs constitute 3 to 5 per cent of the total costs, and consequently they are often the decisive factor in the cost-efficiency of the process. The extruder itself is considered the largest energy user in every extrusion line. This is why battenfeld-cincinnati has already equipped all of its extruders with maintenance-free, energy-efficient AC motors as standard for several years. Tests have shown that torque motors offer a further increase in efficiency thanks to their high performance coefficient. This concept is already being applied in modern high-speed extruders. It should be remembered though that the operating range is a decisive factor for both motor types. The nominal operating point where the drive yields its maximum efficiency should always be targeted. Optimized screw geometries for every application also contribute to saving energy on the extruder, as does tempering of the processing unit. Here, the machine manufacturer relies on concepts that are highly flexible, provide excellent contact with the barrel and offer a large surface for optimized heat dissipation. Therefore battenfeld-cincinnati takes great pains to advise its customers on their choice of the right extruder, and its comprehensive product portfolio includes the ideal equipment for every processing task.

Example of an energy monitoring evaluation (Photo: battenfeld-cincinnati)

However, optimizing only the extruder is not sufficient for sustainable energy consumption cuts on the entire extrusion line. So battenfeld-cincinnati offers an energy monitoring system to ascertain exactly how much energy each component of a complete line consumes. The system measures all energy flows in the line and compiles an energy distribution chart. Thus processors get an accurate overview of how much energy is being consumed at each point. This enables reliable comparisons on the basis of which practicable energy saving measures can be devised so that the production process becomes more efficient.

battenfeld-cincinnati has also focused on the energetic optimization of the downstream components for some time. Cooling and haul-off equipment and cutting devices have been continuously improved to achieve more efficiency. One of the latest innovative developments is the Green Pipe downstream concept, which has significantly improved the energy efficiency in cooling pipes. Instead of conventional cooling baths, where every spray tank operates with a separate water circuit, the Green Pipe system has all spray tanks connected to each other, so that the water is pumped through all tanks from the last back to the first according to the countercurrent principle. This raises the return temperature to the cooler significantly, which increases the scope for making use of free cooling. This in turn reduces the load on the compressor and consequently the delivery rate of the pump. The temperature level of the waste heat is also raised sufficiently to permit exploitation of the waste heat for energy reclaim.

This shows that battenfeld-cincinnati offers not only efficient extruders but also a holistic concept to save energy and thus a sustainable cost cutting solution in the extrusion process.

source: www.battenfeld-cincinnati.com

Photo: Geberit

KWD-SHK, 01.06.2011. The accreditation, which applies to Geberit’s innovative Mapress Stainless Steel and Carbon Steel, covers all dimensions of Geberit Mapress  piping up to 108mm making it the natural choice for all types of fire safety installations. Following a rigorous testing process, Geberit Mapress is now the approved press fitting pipework for use on all fire protection systems including wet and dry sprinkler systems, pre-action systems, low pressure water spray and mist systems, foam water sprinkler systems, deluge systems, hydrant systems and extinguishing water pipes.

Geberit Mapress is packed full of practical installation benefits, as with all pipework connections pressed on to the tube by using just a press-fitting tool, this method can be used on a wide range of applications and offers a practical, durable and reliable alternative to traditional methods. Installation is fast while safety is assured due to the innovative pressing indicator which reveals visible leak paths to enable unpressed joints to the detected and fixed before the pressure test.

Due to its labour saving qualities and sheer durability, Geberit Mapress is the number one choice for fitting fire protection systems in applications where a fast turnaround is imperative, such as hotels, care homes, retail outlets, schools and hospitals. Requiring no adhesive or solvents, press-fit connections can be easily rotated into tight spaces, making Geberit Mapress particularly suitable for retrofit projects and complex installations, as well as for those requiring a fast turnaround.

The very first to be approved by the LPCB and the press fitting system of choice for installers throughout the industry, Geberit Mapress offers the very best results for fitting fire protection systems.

Mapress range of pipes and fittings

Photo: Geberit

The Mapress range of pipes and fittings come in stainless steel, carbon steel, copper and CuNiFe and our Mepla pipe are made from a composite of metal and plastic. Mapress and Mepla systems can be used in a wide variety of applications including heating, cooling, gas and industrial facilities.

A key benefit to Geberit’s Mapress and Mepla system is that the fittings are designed so that any connections not pressed during installation are automatically detectable during the leak test, providing the installer with a fail-safe method of checking for unpressed joints. Also, the indicator foils on Mapress fittings provide and additional security as the foil is removed after the correct pressing operation. The indicators are colour coded by material type and are branded with the dimension size to aid identification and processing.

Contact:  Geberit UK, Warwick, Warwickshire, United Kingdom, sales@geberit.com, www.geberit.co.uk.

Borouge Innovation Centre as it should look after completion

Borouge, a leading provider of innovative value creating plastics solutions, has ordered a complete polyolefins (PO) pipe extrusion line from KraussMaffei Berstorff for its new Innovation Centre in Abu Dhabi.
The order package comprises the KME 60-36 B/R single-screw extruder in the successful 36D Series, the KM-RKW 32 and KM-RKW 33 pipe heads, and corresponding downstream components for the diameter range from 12 to 63 mm. The system will be used in the development laboratory in Abu Dhabi for different tests and development projects.

Multifunctional use and high line speeds
We chose KraussMaffei Berstorff because we are impressed with the outstanding quality of the machines, their extreme efficiency and high flexibility in the use of different materials”, emphasized Petri Lehmus, Innovation Centre Manager from Borouge. “In our laboratory the system will test development stages of various PO materials such as HD-PE, LD-PE, PP-HM or PP-R and also produce pipes in the diameter range of 12 to 63 mm at line speeds of between 2.8 and 100 m/min“, added Lehmus. The line is equipped with two pipe heads in order to ensure a quick and flexible product change.

Proven 36D series for new developments

KraussMaffei Berstorff single-screw extruder KME 60-36 B/R (photo: Kraus Maffei)

“We are very proud that our successful concept of the 36D long processing unit, which has enjoyed the highest possible recognition in the market for many years, is also being used for new developments, tests and customer demonstrations at one of the most renowned material manufacturers”, enthused Andreas Kessler, General Sales Manager for Extrusion Technology at KraussMaffei Berstorff.

“Thanks to the sophisticated – in process engineering terms – barrier screw concept, we are convinced that this series will satisfy the demands in the processing of new materials to the highest possible extent. We are also expecting an increase in the number of orders for polyolefins processing”, added Kessler.

Borouge’s Innovation Centre will work together with the European innovation centres of Borealis as well as with local and international educational institutions such as the Petroleum Institute of Abu Dhabi, to further develop the competence of polymer science in the United Arab Emirates.

More than 50 international researchers and engineers will focus on innovations for compounding as well as innovative plastics solutions for the infrastructure, automotive and advanced packaging industries in close cooperation and partnership with Borouge’s customers throughout the value chain, ensuring that specific customer requirements are met.

The pipe extrusion line will be delivered at the end of 2011 and will be started up at the laboratory the following year.

source: www.kraussmaffei.com

KWD-globalpipe, 29.09.2011. After a period of weakness, probably one reason was the worldwide financial crisis, all PEX types are increasing again in all applications.

Among the PEX pipes, PE-Xa gets back increasing interest while PE-Xb is more or less confined to South Europe, Asia and aluminium composite pipes. PE-Xc keep its clientele, but cannot attract new users. A further confirmation of the positive PE-Xa trend is, that many machine builders report increasing sales with PE-Xa pipe extrusion lines.

Although PE-RT volumes are growing, they grow mainly in Floor Heating Systems (UFH) and aluminium composite pipes. The number of PE-RT extruders is strongly increasing, as producint on these units is relatively easy and very cost effective – the reverse of the medal is increasing pricing pressure.

Particularly in Germany many of the most important European manufacturers are located, or to be more precise: Six from the first eight largest PE-RT pipe manufacturers are German companies.

more Information: KWD Market Report “PEX and PE-RT Heating & Plumbing Pipes, worldwide 2011″