ABS/PE Core Pipe Extrusion Line

This extrusion line is specifically designed for multi-layer core pipes, drainage systems, and industrial conduits, balancing rigidity (ABS) and toughness (PE).

Case 1: Municipal sewage pipe rehabilitation (Southeast Asia)
A customer in Vietnam used the JW5120/38 to produce 300mm ID ABS/PE sandwich pipe. At an output of 420 kg/h, they achieved 12 hours of continuous operation, producing 2.4 tons of pipe—equivalent to 600 meters of DN300 pipe. The result: 30% faster installation compared to concrete pipes, and no cracks after two rainy seasons of testing.

Case 2: Industrial plant cable conduit (Middle East)
A contractor in the UAE selected the JW590/38 to produce 120mm ID PE core conduit. The lower output range of this line (120-150 kg/h) is ideal for small-batch, high-precision orders. They reported a first-pass yield of 95% and zero ovality on 6-meter pipe lengths.

Two models cover a wide diameter range
JW590/38 covers small to medium pipe diameters (75-153mm), suitable for building drainage and cable protection.
JW5120/38 covers large municipal sizes (144-370mm), reducing the need for a second machine.

Energy-efficient 38:1 L/D screw
Unlike standard 30:1 screws, the 38:1 design provides:
Lower melt temperature (reduces ABS material degradation)
Higher filler acceptance (up to 40% calcium carbonate without damaging the pipe)
5-8% energy savings per kg of output

Stable output for core pipe structures
Core pipes typically have a foamed or hollow intermediate layer. The JW series uses a grooved feed section and a barrier screw to prevent fluctuations—a common issue on other lines. Users report output fluctuations below ±2.5%.

Fast material changeover (ABS ↔ PE)
The screw geometry and cooling system allow a complete material changeover (including purging time) within 45 minutes. This is a game-changing advantage for processors that produce both ABS and PE orders daily.

Each production line undergoes a 5-stage quality control process before shipment. Here is the actual process:

Stage 1: Raw material verification
Test: Melt flow index (MFI) of incoming ABS/PE pellets
Standard: Within ±5% of supplier datasheet
Action: Reject batch if out of specification (prevents fluctuations or gels)

Stage 2: In-line dimensional monitoring
Equipment: Laser ultrasonic thickness gauge (measures ID and wall thickness every 0.5 seconds)
Target for JW590/38: 75mm ID → tolerance ±0.3mm; 153mm ID → ±0.5mm
Real case: During a trial run for a German buyer, the gauge detected a 0.4mm deviation at 140mm ID and automatically adjusted the vacuum calibration tank within 2 seconds.

Stage 3: Hydrostatic pressure test (on sample rings)
Procedure: Cut 300mm pipe sample, cap ends, pressurize to 1.5 times working pressure (e.g., 15 bar for a 10 bar pipe)
Hold time: Constant pressure for 1 hour
Pass condition: No visible leakage or blistering

Stage 4: Ovality and straightness check
Method: Rotate pipe on V-blocks while measuring with a dial gauge
Limit: ≤ 1.5% of outer diameter
Example: For 200mm ID pipe, ovality must be ≤3mm. Our JW5120/38 achieves average ovality of 1.2%.

Stage 5: Accelerated aging test (for ABS-rich compounds)
Condition: 500 hours in UV aging chamber (simulates 2 years outdoor storage)
Inspection: Surface cracking or color change. Pass = no visible change.

Q1: Can this line use 100% recycled ABS or PE?
A: Yes, but with minor adjustments. The JW series is equipped with a two-stage screen changer (optional). For recyclate with contamination risk, we recommend using a 60/40 virgin/recycled blend for the first month. A customer in the Philippines used 80% recycled PE on a JW5120/38 to produce non-pressure drainage pipe—output dropped to 380 kg/h, but quality remained stable.

Q2: What is the actual power consumption of the JW590/38?
A: At 135 kg/h output (mid-range), the main extruder motor consumes approximately 38-42 kWh. The entire line (including vacuum tank, puller, and cutter) consumes about 55-60 kWh. Compared to competitors: about 15% lower energy consumption per kg of pipe.

Q3: How often do the screw and barrel need replacement?
A: For 100% virgin ABS or PE, expect 25,000-30,000 hours of operation before 0.2mm diameter wear. For glass-filled or high-recyclate materials, check wear at 15,000 hours. We offer nitrided steel as standard (HV 950-1000); bimetallic is optional.

Q4: My factory has limited space. Can the line be split?
A: Yes. The JW590/38 requires a minimum length of 18 meters (extruder + 6m vacuum tank + 4m puller + 3m cutter). The JW5120/38 requires 24 meters. Both can be arranged in an L-shape using a 90° transfer conveyor—we have done this for a customer in Malaysia.

Q6: How long does it take from arrival to production start-up for a new line? What on-site support do you provide?
A: For JW590/38 or JW5120/38, the standard installation and commissioning process is as follows:
Mechanical installation: 2 skilled workers + 1 forklift driver, about 2–3 days to position and connect the entire line (including extruder, vacuum calibration tank, spray cooling tank, puller, cutter, and stacking rack).
Electrical and control system wiring: 1 day (we provide numbered plugs and clear wiring diagrams; no dedicated electrical software required).
No-load run and safety test: 0.5 day.
On-material commissioning and parameter optimization: 1–2 days. Our engineer will set screw speed, haul-off speed, vacuum level, and cooling zone temperatures for different pipe diameters on site, and record a standard operating video for reference.
Real case: A customer in Thailand received a JW590/38, completed installation on day 3, and produced the first qualified 110mm core pipe (98% yield) on day 5. We provide 7–10 days of on-site follow-up production support (depending on order size) and promise a 24-hour response to remote support requests. For overseas customers, we also support remote first start-up guidance via video conference—the fastest customer produced pipe independently on day 4 after arrival.

Q7: How to quickly change pipe wall thickness? Does it require changing the die or sizing sleeve?
A: Wall thickness adjustment on the JW series is very flexible, depending on the magnitude of the change:
Fine adjustment (within ±0.5mm): No hardware change needed. Simply adjust haul-off speed and screw speed simultaneously via the HMI touchscreen (faster haul-off → thinner wall; faster screw → thicker wall). The vacuum calibration tank pressure can also assist fine adjustment. A skilled operator can complete this within 5 minutes.
Medium adjustment (±0.5–2mm): Usually requires changing the sizing sleeve (different ID copper or stainless steel sleeves for different wall thicknesses). Sleeve change takes about 10 minutes for JW590/38 and about 15 minutes for JW5120/38. For different wall thicknesses under the same outer diameter, the die body does not need changing; only the mandrel position needs adjustment.
Large adjustment (beyond 2mm or changing pipe series): Requires changing the die and mandrel combination. For example, switching from SDR17 to SDR11, we recommend customers purchase the corresponding die components in advance. We provide a die interchangeability table. A customer in Malaysia using a JW5120/38 to produce 250mm core pipe switched from 9mm to 12mm wall thickness in just 20 minutes (changing sizing sleeve + adjusting haul-off).
Recommended practice: For lines that frequently change wall thickness, consider purchasing an optional quick-clamp sizing sleeve set, which requires no screw disassembly and reduces changeover time to less than 5 minutes.