helix II PO Pipe toolings and coat coating dies
The new generation of PO pipe tooling
Customized mono- and multi-layer tooling for a wide range of customer requirements
The modular helix II platform combines proven VSI distribution technology with application-specific tooling concepts and a wide range of optional process optimization solutions. From microducts to extra-large diameter pipes and advanced coating applications, helix II provides flexible solutions for virtually every PO pipe extrusion requirement.
With its new helix II series, battenfeld-cincinnati offers an extensive portfolio of mono- and multi-layer PO pipe toolings that can be configured to meet a wide range of application requirements. The unique VSI dies feature a patented 2-step distribution concept consisting of a spiral mandrel for preliminary distribution and a lattice basket distributor for final melt distribution, enabling high throughput rates with compact die dimensions. The modular design also allows individual adaptation to customer-specific requirements. As the market and technology leader in large-diameter PO pipe extrusion, battenfeld-cincinnati has successfully realized numerous projects for pipe diameters exceeding 2 m. In addition, the portfolio includes modular coating dies that can be adapted to a wide range of coating applications.
Your Advantages:
- Modular expansion for multilayer applications
- Reduced energy consumption
- Easy retrofit solutions for existing extrusion lines
- Excellent homogenization
- Wide processing window
- Larger range of applications in terms of pipe diameters
- Consistent, reliable product quality for all pipe dimensions
- Precise wall thickness distribution and therefore raw material savings
- Low pressure loss
- Modular design
- High throughput
Our Offer:
- Equipped with a patented 2-step distributor concept consisting of a spiral mandrel for preliminary distribution and a screen basket distributor for fine distribution
- Reduced gloss streak formation through gentle melt distribution
- Compact design and consequently easier handling in assembly work
- Smaller volume shortens color change times
- Easy cleaning and maintenance thanks to separate distribution systems for each layer
INTELLIGENT PROCESS SOLUTIONS
Besides the proven die head technology, helix II offers intelligent process optimization systems that increase productivity, reduce raw material consumption and improve product quality.
| ICA | Intelligent Centering Adjustment | The Intelligent Centering Adjustment system enables fast and reproducible inline centering. Mechanical or servo-driven adjustment minimizes start-up times and significantly reduces material waste. | ||
| IOA | Intelligent Operation Adjustment | Combining Intelligent Centering Adjustment with the continuously adjustable melt gap creates an automated die head solution for optimum production flexibility.. | ||
| PMA | Pipehead Measuring Aid | PMA supports fast die head setup through sensor-assisted positioning and stored recipes, ensuring repeatable production conditions with minimal scrap. | ||
| Heat Insulation | Optional insulation jackets reduce energy consumption by up to 30%, improve operator safety and ensure homogeneous temperature distribution. |
VSI special mono- and multi-layer toolings
The customized VSI multi-layer tooling can be combined with either spiral mandrel, radial or side-fed distributors as desired. Depending on the materials to be processed, the optimal distribution concept is used in each case.
Your advantages:
- The ideal distribution concept for your material
- Minimal expense for servicing and cleaning of the critical flow surfaces thanks to strategically positioned parting lines, without dismantling of the other components
- Long tooling service life
- Application specific coatings available for wear protection, optimization of flow behaviour and surface sealing
Our offer:
- Top-quality distribution of the functional layers across the circumference and therefore raw material saving
- Mechanically and thermally homogeneous melt distribution
- Minimal residence time range for materials which start a process of cross-linking or thermal degradation following melting (e.g. PEX-b and EVOH)
Melt distribution concepts to suit all areas of application:
- VSI
- Spiral mandrel distributors
- Side-fed distributors
- Spider-type mandrel pipe heads
- Simple, compact radial distributors
Application areas from:
helix II 20 VSI PO Pipe tooling for the production of Microducts from 5 mm pipe diameter...
… to helix II 3000 VSI large diameter pipe tooling for the production of water-, wastewater and mining pipes.
helix II – EAC (Efficient Air Cooling) Internal Pipe Cooling for VSI-T Toolings
With the EAC internal pipe cooling system, battenfeld-cincinnati has set new benchmarks and enabled higher throughputs. The advantages of the proven VSI pipe dies are enhanced by additional internal pipe cooling with an air current against the extrusion direction.
Your advantages:
- More efficient production by reducing the required cooling length by 30 % - 50 %, alternatively the throughput can be increased accordingly
- Improvement of the pipe geometry (pipe roundness)
- Energy savings thanks to the use of exhaust air from internal pipe cooling ,e.g. for pre-heating granulates
- Simple retrofitting of existing VSI toolings
Our offer:
- Proven EAC system for pipe diameters from 63 - 3,000 mm and wall thicknesses up to 120 mm
- Very powerful ventilators
- Ventilator speed can be varied with the aid of a frequency inverter according to process requirements
- To reduce sound emission, the ventilator is sound-insulated (max. 85 dBA at a distance of 1 m)
- Permanently installed exhaust air system with thermal insulation
- Air filter integrated as standard for enhanced operational safety and protection of system components
OPTIMELT – Active Melt Cooling for Thick-Wall Pipe Extrusion
OPTIMELT actively reduces melt temperature directly before the die head. The system minimizes sagging, improves pipe geometry and enables higher throughput rates while reducing cooling length and raw material consumption.
Your advantages:
- Reduced sagging
- Lower ovality
- Improved thermal homogeneity
- Higher productivity
- Enables the production of pipe wall thicknesses above 100 mm
- Independent from EAC
- Retrofit available
FDC – Fast Dimension Change with Adjustable Melt Gap
battenfeld-cincinnati also offers pipe heads with adjustable melt gap for FDC (fast dimension change) – the dimension change system for pipe extrusion lines. Basically, adjustable melt gaps for full-layer and coating dies can also be installed in conventional pipe extrusion lines.
Your advantages:
- Automatic pipe dimension change during production
- Significantly faster changeovers when changing pipe dimensions.
- Increased safety when changing large-diameter dies
- Efficient pipe extrusion line with high throughputs
- High flexibility in pipe geometry and production planning
- Low energy consumption and highest productivity by high-performance extruders with inner pipe cooling system
- Easy handling due to Industry 4.0-compatible control system
- Excellent pipe quality with homogeneous pipe surface and even wall thickness distribution
Our offer:
- Adjustable melt gap with an electric motor available in sizes from 63 to 1,600 mm
- SDR classes from 11 to 33 as standard; additional SDR classes (e.g. SDR 9–26) available on request.
- Adjustment almost independent of melt pressure, as only the die/mandrel area is being adjusted
- Large diameter ranges with changeable die and mandrel extensions
- Can be used in combination with the effective melt cooling system Optimelt
- Retrofit possible for existing pipe heads
INTELLIGENT AUTOMATION
The helix II platform can be equipped with intelligent automation solutions that simplify setup, improve process stability and reduce material waste. By combining advanced centering technologies with automated die adjustment, productivity and product quality can be further enhanced.
ICA – Intelligent Centering Adjustment
Intelligent Centering Adjustment (ICA) enables fast and reproducible inline centering of the die head. The mechanical or servo-controlled adjustment reduces changeover times, significantly lowers material consumption through optimum wall thickness distribution, and ensures precise wall thickness control.
Your advantages
- Fast and reproducible inline centering
- Reduced changeover and start-up times
- Optimum wall thickness distribution
- Reduced material consumption
- Mechanical or servo-controlled adjustment
- Compatible with inline wall thickness measurement systems
IOA – Intelligent Operation Adjustment
Intelligent Operation Adjustment (IOA) combines Intelligent Centering Adjustment (ICA) with the continuously adjustable melt gap (FDC). This integrated solution enables automated die adjustment for maximum production flexibility, improved process stability, reduced changeover times, lower material consumption, and optimum wall thickness distribution.
Your advantages
- Combination of ICA and FDC
- Increased production flexibility
- Improved process stability
- Reduced changeover and start-up times
- Optimum wall thickness distribution
- Reduced material consumption
- Optimized product quality
Small Diameter & Functional Pipe Solutions
helix II 32 VSI-MD
Developed for modern microduct production with throughput rates up to 900 kg/h. Suitable for mono- and multilayer pipes, silicone layers, ribbed inner surfaces and inline wire insertion.
5-Layer PERT Pipe Head
The new helix II 32-5 VSI enables highly accurate production of multilayer heating pipes with EVOH barrier layers while minimizing residence times and material consumption.
Color Stripe Switching
Integrated switching solutions enable rapid color changes while minimizing material waste and downtime.
Your advantages:
- Simple and cost-efficient implementation of individual bundle geometries
- Many different bundle geometries can be produced with one basic tooling
- Pipe bundles and coating do not stick together (thermic separation)
Our offer:
- Mono- or multi-layer coating of pipe bundles
- Special pipe guidance inside the tooling
- Option: frequency-controlled vacuum pump
coat – pipe coating dies
The melt distribution systems of the coat tooling can be configured to meet specific product requirements. For example, VSI two-step distributors can be used as universal distribution systems for a wide range of melt viscosities. This enables the production of pipes coated with HDPE, PP or recycled HDPE using the same coat tooling.
Your advantages
- No time-consuming centering of the individual layers required thanks to optimized melt distribution
- Excellent wall thickness distribution for reduced raw material consumption
- Low melt temperatures at high output rates due to moderate melt pressure
Our offer:
- Modular design for each individual layer to optimize flow geometry
- Double side-fed distributors with smear threads can be used for the outer layer (e.g. PEX-b) and the inner layers (e.g. adhesive layer, EVOH, adhesive layer)
- Side-fed distributors for small-diameter pipes with thin walls and residence time-sensitive materials
- VSI technology for pipe diameters from 80 mm, especially for high throughput rates and large wall thicknesses
Typical Applications
- Steel pipe coating
- Aluminium composite pipes
- Corrosion protection
- Functional outer layers
- Adhesive layers
- Telecommunications
Benefits
- Modular design
- Excellent layer distribution
- Short residence times
- Easy cleaning
- Fast colour change
- Compact construction
| VSI | helix II – VSI Werkzeugtechnologie für Mono- und Mehrschichtanwendungen | |
| EAC | helix II – EAC (Efficient Air Cooling) für VSI-T Werkzeuge | |
| FDC | helix II – FDC (Fast Dimension Change) mit verstellbarem Schmelzspalt | |
| ICA | helix II – ICA (Intelligent Centering Adjustment) | |
| IOA | helix II – IOA (Intelligent Operation Adjustment) = ICA + FDC | |
| PMA | helix II – PMA (Pipehead Measuring Aid) |
