Start a PVC pipe manufacturing Plant

(156) Start a PVC pipe manufacturing Plant

• Polyvinyl chloride (PVC) is created from a combination of vinyl and plastic. Experiments to create a vinyl chloride polymer were first done in the mid-1830s, but the solid product created in the lab was simply an oddity, without any apparent use at that time. Additional experimentation in the 1880s reproduced a solid that withstood high heat exposure, but it was ignored in commercial applications due to the inflexibility of the product. Not until the 1920s did scientists attempt to use co-polymers of vinyl chloride. These were easier to produce and created an extremely durable substance. The first experimental pipes made from a co-polymer of polyvinyl chloride were first produced in 1932. Three years later, commercial production began. The first commercial pipes were used in applications to transport water, sewage and waste water, and for the movement of chemicals.

Preparing Ingredients

• The first step in manufacturing PVC pipes is to prepare the ingredients. PVC is created in a chemical process that bonds the vinyl and chloride. The process involves the polymerization of monomer vinyl chloride (VCM). Most manufacturers use suspended polymerization that involves use of a polymerization reactor to mix chemicals and a polymerization initiator. The resulting PVC resin is suspended in water and then removed for degassing and water removal, which is accomplished by use of a centrifuge. The product is then dried and turned into a granulated dust for transportation to the manufacturing plant, where it will be heated to the melting point. Early manufacturing melted the dry powder as a sheet on a roll mill. Once this was done it was molded into a solid product that was ready to be rolled.

Additives

• Early PVC production created a rigid and stiff product. As a result of experimentation with other polymers and oil products during the 1950s and the subsequent decades, the PVC product improved dramatically. While formulas for PVC are patented by individual companies, most modern PVC ingredients include various types of stabilizers and lubricants to facilitate processing. Colors are also added during the manufacturing process to indicate the appropriate use of the piping. Dark grey pipe is used for industrial pressure applications, white and blue pipes indicate cold water uses, and green is used for sewer applications.

Extrusion

• While rolled PVC was produced beginning in the 1930s, no extrusion process to form PVC pipe was perfected until the 1950s and 1960s. Modifications to such processes are still underway, but today there are two predominant types of PVC pipe--cellular core and solid wall. Three separate layers are extruded to create the cellular core pipe, with hard outer layer walls sandwiching a cellular core center. All three layers are immediately incorporated into one pipe during the manufacturing process. Solid wall PVC pipes are formed in a single manufacturing step. PVC pipe is extruded to meet industry-standard 10 and 20 foot lengths. Pipes are tested for compliance with industry and government standards for durability and the ability to withstand pressure.

How is it Made?

• PVC pipes are created by starting with a molten mixture of the material and shaping them around a cast. The casts are made to be the exact width of the pipe. The mixture is poured into a cast and surrounded by an outer shell. The complete set is then placed into an oven to be cooked. Once the pipe has solidified, it is cooled and moved into finishing. Sections of the pipe are then cut based on common sizes and needs. The sections are then coated in a chlorine solution to prevent harmful bacteria from growing during shipping and use. Once the coating is dried, the ends of each section are finished. If the pipe is a smooth connection, the top of the pipe is sanded down to ensure a perfectly flat surface. For fitted pipes, a machine engraves a series of grooves into the pipe. As the grooves are cut, high-pressured water is sprayed on the pipe to remove excess PVC fragments. After the grooves are added, the ends are smooth and the sections are sent into testing.

Quality Control

• Because PVC pipes are used in many housing and commercial construction applications, it is important that each pipe is tested to ensure quality. To do so, the pipes are tested for their seal, connection (on grooved sections), and strength. The seal tests are conducted by adding a special cement to the pipe and allowing it to dry. Once this is complete, a series of liquids are passed through the pipe at high pressure. If no leaks occur, the cement is removed and the section is cleaned. For fitted pipes, a similar process takes place without the cement. The final test of the pipes is to ensure their strength. This is completed by using several presses that push weight down on the pipe. If the section does not break or show stress points, it is sent for packaging and shipping. If a section fails at any point in the process, it is sent back to be melted down and re-constructed.

PVC pipe manufacturing machine, PVC pipe machine - YouTube
	www.youtube.com/watch?v=8sRY_ySIEXE12 Jul 2009 - 1 min - Uploaded by pipeextrusion PVC pipe manufacturing machine, PVC pipe making machine, upvc/cpvc ... 3D Pipe Manufacturing and Fitting Processby ...

PVC Twin-Pipe Production Line

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