Bahrain Pipes manufactures pipes and system solutions for various applications. These include pipes for hot water, cold water and gas supply, pipes for sewage systems and pipes for data transport systems made of PE, PP-R and PVC. More than 20 extrusion lines are in operation at the production site in Manama, Bahrain, for the production of small and large pipes, coiled pipes and corrugated pipes. A large injection molding machine park completes the extruded pipes with its own fittings to create complete systems if required. The company, which was founded in 1996, therefore has enormous expertise and a broad portfolio and has a good reputation not only nationally but also internationally. Bahrain Pipes selected the innovative extruder solution with dosing station from its long-standing machine supplier battenfeld-cincinnati primarily because of the material cost savings combined with increased flexibility. “The customer has upgraded an existing pipe line with our extruder combination and is now able to produce 3-layer pipes with a highly filled middle layer,” explains Gernot Dorn.
High filler contents are of great interest for the production of PVC pipes, as the material costs still make up the lion's share of the production costs. Chalk contents of up to 65 parts (ppH) are quite common. However, the high contents do not make the production and dosing of the typically used premixes very easy. On the one hand, the high chalk content leads to increased machine wear due to its abrasiveness, both in the heating/cooling mixer and in the conveying lines, and on the other hand it can lead to demixing before being fed into the extruder, which in turn leads to reduced material homogeneity. These disadvantages are a thing of the past with the new dosing unit. Pipe manufacturers such as Bahrain Pipes can now use premixes with a low chalk content and feed the remaining quantity directly into the extruder. On the one hand, the standardized premix reduces wear in the heating/cooling mixer and, on the other hand, allows higher overall outputs, as high chalk content enables longer mixing times and smaller quantities due to its large surface area. At the same time, the standard mix in combination with the dosing unit enables product-specific recipes to be configured on demand directly on the extruder. To ensure a smooth process, the dosing unit is equipped with a closed chamber in which the chalk is kept in constant motion to prevent bridging and to guarantee dust-free operation. It is fed directly into the main extruder, the twinEX 93-34R. This is equipped with a specially adapted and wear-resistant screw geometry and ensures perfect homogenization of the middle layer. The conical conEX NG 54 twin-screw extruder ensures shiny and absolutely smooth inner and outer layers for the up to 250 mm wastewater pipes produced in Bahrain. To the customer's complete satisfaction, the line has recently been running at an output rate of 750 kg/h.
About battenfeld-cincinnati
battenfeld-cincinnati is a leading manufacturer of energy-efficient and high-performance extruders and complete extrusion lines according to customer-specific requirements. battenfeld-cincinnati offers tailor-made solutions for a wide range of applications in the field of pipe, profile, sheet, thermoforming sheet and pelletizing from a large portfolio of single- and twin-screw extruders, dies, downstream equipment, calanders and calander feeders. Customers are served by production sites in Germany, Austria, China and the USA, as well as a comprehensive global sales and service network. battenfeld-cincinnati is a company of the Davis-Standard Corporation, USA, and stands for quality and sustainability in plastics extrusion worldwide.
About Bahrain Pipes (BP)
Bahrain Pipes (BP), established in 1996, has an outstanding reputation in the local and region market, produces the highest quality plastic pipes and fittings using the latest technology machinery and the most advanced materials. It gradually expanded business throughout the GCC region, Middle East and East African countries. Bahrain Pipes products accommodate for a wide range of applications such as drainage, sewage, drinking water, irrigation, cable ducting…etc. These products are produced using an extensive range of materials and are produced in conformance to German, British, American, European and Australian standards. In order to keep abreast of the latest technology, Bahrain Pipes is an active member of the Plastics Pipe Institute, USA. Bahrain Pipes is considered the pioneer in the manufacture of Polybutene-1 hot and cold plumbing and heating systems in the Middle East. It produces an approximate output of 16,000 tons per year, with a substantial share of its production being exported mainly to the GCC, Middle East and North Africa.
