High-speed Energy-Saving Polyolefin Pipe Extrusion Line

This extrusion line is widely used in municipal water supply, gas transmission, industrial pipelines, drainage, and cable protection pipe applications. The modular model range allows you to match production capacity to project requirements.

Real-world case: A pipe manufacturer in Uzbekistan used the JWG630 line to produce 630 mm OD PE pipes for a regional irrigation project. At an output of 1,050 kg/h, they completed 12 km of pipe in 18 days – 30% faster than their previous line.

2.1 High output with lower energy consumption per kg
JWG630 achieves 1,050 kg/h with a 280 kW motor → 3.75 kg/kWh
Compared to traditional lines (approx. 2.8 kg/kWh) → energy saving of about 34%.
All models feature high-torque JVS extruders (60/40, 75/38, 90/38) combined with optimized polyolefin screw geometry.

2.2 Wide diameter coverage – one machine for multiple uses
From 16 mm to 630 mm, serving both small pipe producers and large-diameter pipe contractors. No need to purchase multiple incompatible lines.

2.3 Fast model changeover
Screw L/D ratios (40 for JVS60, 38 for others) allow rapid material change (PE to PPR in 40 minutes).
Downstream sizing sleeves and vacuum tanks are designed for the given range – e.g., JWG315 covers Φ110–315 without replacing the main unit.

2.4 Powerful drive system
Main motor power steps up progressively (90, 110, 132, 160, 250, 280 kW) matched to torque requirements. Redundant design for 24/7 continuous operation – bearing temperature stays below 75°C even at 95% load.

2.5 Energy-saving features
Variable Frequency Drive (VFD) as standard on all main motors.
Ceramic heater bands + insulation covers reduce heat loss by 20%.
Screw cooling (water or oil, depending on model) prevents energy waste from over-shearing.

We follow a four-stage quality control scheme compliant with ISO 4427 / ASTM D3035 for polyolefin pipes.

Stage 1 – Process monitoring
Melt pressure and temperature sensors installed at the die head (accuracy ±0.5%).
Ultrasonic wall thickness online scanner (non-contact) – 8 points per second.
Melt Flow Rate (MFR) sampling every 2 hours to ensure resin consistency.

Stage 2 – Dimensional control
After vacuum sizing and cooling tank, laser OD gauge and ultrasonic thickness gauge feed data back to the closed-loop haul-off control system. For example, when producing Φ450 mm pipe on JWG450, ovality is kept within 0.5% (ASTM allows 1.5%).

Stage 3 – Mechanical property testing (offline)
Samples taken per production shift undergo:
Hydrostatic pressure test (100 hours, 20°C, 1.5× nominal pressure) – all models pass at their maximum diameter.
Longitudinal reversion – PE100 ≤2% (actual results typically 1.2%).
Tensile strength and elongation at break – elongation ≥350% for PE.

Stage 4 – Final inspection and traceability
Each pipe is laser-engraved with a 2D code containing:
Model, production date, shift, operator
Average wall thickness, OD, pressure test results
Batch number of raw materials

Real QC case: During a 3-month production run of JWG315 for a German gas company, the line achieved a 99.7% first-pass yield (only 0.3% scrap due to minor surface scratches). The customer's third-party audit confirmed wall thickness deviation <0.2 mm over 500 m of pipe.

Q1: If I need to produce Φ200 mm PE pipe with an output requirement of 500 kg/h, which model should I choose?
A1: JWG250 (Φ75–Φ250, max 550 kg/h) is very suitable. Its 132 kW motor runs at about 80% load, leaving margin for higher output when using high-MFI resins. If you later plan to produce Φ315 mm pipe, upgrade to JWG315.

Q2: What is the actual energy consumption per ton for JWG630?
A2: At full output (1,050 kg/h, 280 kW), energy consumption is about 267 kWh/ton. With energy-saving mode (using grooved feed sleeve, reducing screw speed while maintaining same output), it can drop to 255 kWh/ton. Compared to old lines at 350–400 kWh/ton, savings of 25–30%.

Q3: How long does it take to change from PE to PP material?
A3: Using purge compound, about 45 minutes for the JVS75/38 model (JWG160/250/315). The screw design has a compression ratio optimized for both materials. Purging requires about 80 kg of purge resin.

Q4: What is the typical service life of the extruder barrel and screw?
A4: With nitrided steel (HV 950–1000) plus bimetallic liner, normal life is 25,000–30,000 hours before re-nitriding is needed. For materials containing abrasive fillers (e.g., talc-filled PP), tungsten carbide coating is available – life can extend to over 40,000 hours. Many customers use them continuously for 10 years without replacement.

Q5: Does the line support online printing or marking?
A5: Yes. We can provide an optional hot stamp printer or inkjet printer after the cooling tank. For JWG450 and JWG630, a third-party embossing wheel can also be integrated for continuous text marking.

Q6: When changing pipe diameters within the same model, how is wall thickness uniformity ensured?
A6: The line is equipped with an automatic centering system (servo-driven). For example, on JWG160, switching from Φ110 mm to Φ160 mm takes only 8 minutes, and after autocalibration wall thickness deviation remains within ±0.1 mm.

Q7: What is the MOQ for spare parts kits?
A7: We recommend a basic spare parts kit (heater bands, thermocouples, one spare screw tip, seals) – MOQ is 1 set. For screws and barrels, lead time is 15 days.