What is the common feature for Kyiv and New York, London, Tokyo? - pipes. They are everywhere. Water, gas, and sometimes even the Internet and communications get to our houses using pipes. They must be especially durable and have a long life cycle.
But what is the way polyethylene pipes are made?
Six modern lines at Planet Plastics Plant can produce about ten thousand tons of pipes annually for any purposes.
The polyethylene pipe begins with polyethylene pellets.
It is purchased from the most famous suppliers in the world.
Depending on the pipe type, pellets may be black or white.
Following the laboratory tests pellets are transferred to the production shop.
Now human’s work is almost unnecessary.
The process is controlled by a computer.
The operator only needs to set the required diameter and thickness of the pipe wall.
The equipment will calculate the amount of required raw material, temperature and speed with which the line should work.
The speed of work depends on these tracks. They are located almost at the end of the line and, depending on the set parameters, pull a pipe at a rate of two or twenty meters per minute.
At the beginning of the line, there is an accurate gravimetric system.
Following the signal of the computer, it measures the required amount of polyethylene and pours it into an extruder.
The extruder heats pellets to one hundred and eighty degrees and stirs them to obtain a homogeneous mass.
In the cross-section it looks like this: polyethylene pellets enter the extruder chamber and are heated up.
Then the mechanism, like a screw of a meat grinder, presses this mass on a molding tool.
The melted plastic passes between its elements and thus a pipe workpiece is molded.
The pipe workpiece is too hot and unstable.
In addition, the final diameter is not formed.
The workpiece passes through a caliber, where the diameter is formed, and is immediately transferred to the vacuum bath.
Due to low pressure and cold water, pipes of required quality are formed.
It is cooled, but not enough.
There are three other cooling baths with water at room temperature.
The pipe is ready. All that is left to do is to label it.
After every meter, the laser applies a special code. This is a standard, lot number, production date, and other required parameters.
The finished pipe is picked up in huge coils; the coil diameter depends on the pipe size.
When everything is ready, the mechanism releases the coil and it is taken from the workshop.
Ready pipes are tested in our own laboratory.
There we check the strength and the load they can withstand.
And the pressure inside the pipe is almost twice of that the pipe is designed for.
Such a safety margin is mandatory as it concerns the pipes for water or gas supply.
Planet Plastic Plant produces pipes for water, gas supply, sewage pipes and technical pipes.
The latter are made of secondary raw materials. They are not durable, so they are not used to drain water or gas.
And still pipes for telecommunication lines.
They protect expensive fiber optic cables.
The most convenient way to blow up cables in these pipes is to use a powerful air flow, but for this purpose it is necessary to reduce friction between surfaces, that’s why the internal walls of such pipes are made using a special technology.
They are not smooth, like in other pipes, but have special cuts.
The cable is moving along the cut like in the rails and now it interacts not with the entire inner surface of the pipe, but only with these cuts.
Thus, the friction is reduced and at one time the stacker can blow upto five hundred meters of cable.
To produce a polyethylene pipe, anyway you need to have a dozen of workers, high-quality raw materials, and modern expensive equipment.
But if you want to lay it, two specialists and three tools will be enough: a positioner, an ending trimming tool and a heater.
High accuracy during the installation and 30 seconds of heating - and the pipes are reliably connected with each other.
For many years they will deliver to our dwellings things without which we can’t live now.
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