Pipe Extrusion Workbook

Higher Institute for Plastics Fabrication
WORKBOOK
for
Pipe Extrusion
Practical Course
Prepared by
Pipe Extrusion Department
1st Edition 2009
Page 1
Wo r k b o o k fo r P i p e E x t ru s io n P ra c t i c a l C o u r s e
ACKNOWLEDGEMENT
In its program to continuously improve the quality of instructions at the

Higher Institute for Plastics Fabrication, the Curriculum Steering Committee
initiated the creation of the workbooks for all practical courses being offered
in the Institute. The Committee is headed by Dr. Khaled Al-Ghefaili, and the
members are Dr. Ahmad Al-Ghamdi, Mr. Hiroshi Takeshita, Engr. Issa Al-
Khormi, Mr. Sumio Iwase, Mr. Kazuhiko Sawada, Mr. Sanjay Rawat, Mr.
Zakaria Musa, and Mr. Virgilio Calpe.
This is the HIPF Workbook for Pipe Extrusion for Practical Course. The
contents of this workbook were compiled through the efforts of the members
of the Pipe Extrusion Department, namely, Noli Humpay, Jojie Siojo, Robert
Sistena, Donnel Joya, Subhash Thota, Raffy A. Malanyaon, and Kazuhiko
Sawada (Japanese Expert Adviser). Editing, formatting and design by
Virgilio Calpe.
March 2009
Page 2
TABLE OF CONTENTS
Introduction … … … … … … … … … … … … … … … … … … . 4
Course Objectives … … … … … … … … … … … … … … … … . 5
General Safety Guidelines … … … … … … … … … … … … … ... 6
Grades Summary Sheet … … … … … … … … … … … … … … ... 7
Workshop Activities
Activity 1—Safety in the Workshop … … … … … … … … … … .. 8
Activity 2—Workshop Environment … … … … … … … … … … .. 18
Activity 3—Bilateral Understanding in a Workshop … … … … … . 24
Activity 4—Raw Materials … … … … … … … … … … … … … .. 29
Activity 5—Extruder Machine … … … … … … … … … … … … . 39
Activity 6—Vacuum Bath/Cooling Tank … … … … … … … … … 45
Activity 7—Haul-off Machine /Traction … … … … … … … … … . 51
Activity 8—Cutting Saw … … … … … … … … … … … … … … . 62
Activity 9—Tipping Table … … … … … … … … … … … … … .. 71
Activity 10—Computer Control … … … … … … … … … … … … 77
Activity 11—Mock Operation … … … … … … … … … … … … .. 87
Glossary … … … … … … … … … … … … … … … … … … … . 102
References … … … … … … … … … … … … … … … … … … ... 107
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INTRODUCTION
To produce competent operators for the industry, the theoretical training

must be coupled with enough practical exercises. This workbook was
designed to make sure that the future machine operators develop the skills
and knowledge necessary for plastic pipe processing through practice and
workshops. The activities here are aimed to familiarize the trainees in the
machine parts and their functions, the operating principles and techniques in
a plastic pipe processing.
Page 4
COURSE OBJECTIVES
At the end of this practical course, the trainees will be able to:
1. Better understand the importance of safety in pipe extrusion

processing;
2. Understand the importance of good working environment;
3. Know the materials used in making plastic pipes and the differences
of these materials from each other;
4. Identify machine parts of equipment in pipe extrusion processing and
describe the functions of these machines parts; and
5. Troubleshoot abnormalities encountered in plastic pipe processing.
Page 5
GENERAL SAFETY GUIDELINES
1. Above all, always observe Good Manners and Right Conduct

(GMRC) at all times.
2. Always come on time and observed prescribed break and dismissal
time.
3. Always wear prescribed uniform and safety shoes.
4. Respect all Instructors and Advisers at all times.
5. Do not operate any machines or equipment, such as forklift , hand
pallet trucks, etc., unless with the consent of your respective
Instructor.
6. Eating is not allowed in the workshop premises. Eating is only
allowed during break time in the cafeteria.
7. No sleeping inside the classroom. No smoking at any given time.
8. Always wear prescribed Personal Protective Equipment (PPE) when
inside the workshop.
9. Always observed good relationship with your co-trainees.
10. Maintain cleanliness and orderliness, may it be in the classrooms or
in the shop floor. Don’t litter . Vandalism is strictly forbidden.
11. Be a responsible individual. No horse playing.
12. No mobile phones during class session.
13. Use comfort rooms in the right manner.
14. Everything you do, ask first the consent of your respective Instructor
to avoid any untoward incident.
Page 6
GRADES SUMMARY SHEET

Trainee Name: _________________________ Group: ________
Semester ___ School Year ___________
ACTIVITIES GRADE
Activity 1—Safety in the Workshop
Activity 2—Workshop Environment
Activity 3—Bilateral Understanding in a Workshop
Activity 4—Raw Materials
Activity 5—Extruder Machine
Activity 6—Vacuum Bath/Cooling Tank
Activity 7—Haul-off Machine /Traction
Activity 8—Cutting Saw
Activity 9—Tipping Table
Activity 10—Computer Control
Activity 11—Mock Operation
AVERAGE GRADE
Page 7
WORKSHOP ACTIVITY #1
Safety in the Workshop

THEORETICAL BACKGROUND
Before we proceed with our various activities in the workshop, it is highly

recommended to first pay particular attention to the well being and safety of
each individual performing workshop activities. As the popular slogan in
most institutions says, “SAFETY FIRST!”. It was true yesterday. It is still
true today and will be true tomorrow.
The following questions will be our basis in treating what safety means to us
in our daily workshop activities.
1. Which areas in the workshop floor do you need to pay much
attention? And what kind of attention you have to pay?
2. What are the personal protective equipment needed?
We will tackle those question one by one to ensure a smooth and safe
environment inside the Plastics Pipe Processing Workshop.
PERSONAL PROTECTIVE EQUIPMENT

(PPE)
Why do we have to use Personal Protective

Equipment? Personal Protective Equipment
not only helps protect people from danger,
but also improves their productivity in the
production line.
PPE can reduce the number of potential
injuries and illnesses at works.
These signage can always be seen in a
workplace where wearing of Personal
Protective Equipment is a must.
Page 8
WORKSHOP ACTIVITY #1—Safety in the Workshop
Theoretical Background … continued
A. Wear Work Clothes or Uniform

It is very important for all
trainees to wear work uniform
before they enter the workshop
because uniform (work clothes)
protect your body from burns and
other hazardous objects that might
hurt any part of your body.
B. Wear Safety Shoes

Protect your feet with a
pair of safety shoes or
boots with non-slip soles
and heels .
C. Wear Appropriate Hand Gloves
HIGH TEMP WORKING

HAND GLOVES
HOT SURFACE
D. Wear Eye Goggles

Protect your eyes with
appropriate safety eye wear
(safety glasses, goggles, face
shields) when working in a
workshop under heavy dust
condition.
Page 9
E. Wear Ear Protection
Protect your hearing

with acoustic earmuffs
or plugs when
operating noisy
equipment such as
granulators.
F. Wear Head Protection Cap (Hard Hat)
Protect your head with a hard hat when

performing construction works, machine repairs
and other related jobs with head injury risks.
G. Wear Face Mask

Protect your lungs with the
correct respiratory equipment
(dust masks, cartridge
respirators, gas masks, air packs)
when working in a dusty
conditions, applying chemicals,
working in bins, tanks, silos and
raw materials storage places.
Page 10
OBJECTIVES OF THE ACTIVITY
1. To be able to identify the hazardous areas in the workshop

2. To become familiar with signs and symbols used for safety
3. To become acquainted with the use of Personal Protective Equipment
(PPE)
PROCEDURE
1. Proceed to the machine and try to identify all the potential hazards in
running the pipe extrusion plant.
2. Part I—Identify the safety signs and symbols that are illustrated in
your data sheet.
3. Part II—Identify the Personal Protective Equipment illustrated in
your data sheet, and give their respective uses.
Page 11

Report Form - Page 1 of 6
Cut Report Form and Submit to Instructor
DATA S H E E T
ACTIVITY #1—Safety in the Workshop
TRAINEE NAME GROUP NO.
Part I—Identify the Safety Signs and Symbols

1. Extruder Electrical Cabinet
Symbol for:
2. Back of Extruder Machine
Symbol for:
3. Barrel Heaters
Symbols for:
4. Die Head Assembly
Symbol for:
Page 12

DATA S H E E T
Part I—Identify the Safety Signs and Symbols … continued

5. Vacuum Bath
Symbol for:
6. Cutting Saw
Symbols for:
7. Cutting Saw
Symbol for:
8. Cutting Saw
Symbol for:
Page 13

DATA S H E E T
Part I—Identify the Safety Signs and Symbols … continued

9. Inside Cutting Saw Enclosure
Symbols for:
10. Inside Cutting Saw Enclosure
Symbol for:
11. Tipping Table
Symbols for:
12. Material Auto Conveying System
Symbol for:
Page 14

DATA S H E E T
Part II—Identify the Personal Protective Equipment

1. 2.
3. 4.
5. 6.
Page 15

QUESTIONS & EXERCISES
I. List down 5 safety signs found in the Pipe Extrusion machine.
1. _________________________________________________
2. _________________________________________________
3. _________________________________________________
4. _________________________________________________
5. _________________________________________________
II. List down 5 personal protective equipment you need to work in the
Pipe Extrusion Workshop.
1. _________________________________________________
2. _________________________________________________
3. _________________________________________________
4. _________________________________________________
5. _________________________________________________
Page 16

CONCLUSION & RECOMMENDATIONS
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DATE: __________________ TRAINEE’S SIGNATURE
INSTRUCTOR’S COMMENTS
TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
DATE: __________________ INSTRUCTOR’S SIGNATURE
Page 17
Workshop Environment
A. Clean Workshop
The Pipe Extrusion machines are located in Workshop #4. The Workshop
also houses the Sheet Extrusion and Thermoforming machines, and the
Testing Laboratory. There are two classrooms, staff offices, two comfort
rooms and a Tools and Materials Storage room.
Here everything is well set and clean. Visiting our workshop is much
appreciated. The entrance door is swing type that can be opened wide and
closed quickly. It is designed for easy movement to go inside and outside.
The concrete floor is painted and maintained clean and shiny. Cool air is
supplied from outside using desert cooler to keep the workshop comfortable.
B. Machine Arrangement
The pipe extrusion setup consists of an extruder, the die, a vacuum bath, a
traction, a cutting saw, and a tipping table.
The machines are arranged such that the workshop space is optimized and
there is enough room for Trainees and Instructors to move around during
training.
Page 18
WORKSHOP ACTIVITY #2—Workshop Environment
Big machines are kept in near the walls. The floor have markings for
restricted areas and pathways to ensure visitors safety.
C. Safety Inside the Workshop

Safety is the most important factor during training. The machines must be
kept in good condition. On the first day of training, the trainees are oriented
about their personal safety, workshop rules, and safety on machines.
Before the Trainees do hands-on training, we see to it that they are prepared
and safe, and well oriented about the possible dangers in operating the
machine.
Page 19
1. To know the Workshop #4 Rules and Regulations.

2. To become familiar with the Workshop #4 machine setup.
PROCEDURE
What is in Pipe Extrusion Workshop?

1. Tour the workshop with a Senior Instructor and observe all the things
you can find inside.
2. Write down all the things you observed in your data sheet.
Page 20

DATA S H E E T
ACTIVITY #2—Workshop Environment
What is in Pipe Extrusion Workshop?
______________________________________________________________________________
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Write T if the statement is True and F if it is False.
________ 1. In Workshop #4, Pipe Extrusion Process is one of the courses

being taught.
________ 2. Pipe Extrusion Workshop is clean and organized, and has a

comfortable environment for learning.
________ 3. The long and many machines used in pipe extrusion make the
workshop crowded and unsafe for teaching the trainees?
________ 4. Visitors do not want to visit pipe extrusion workshop because

it is dangerous inside.
________ 5. Trainees must be oriented about personal safety, workshop

rules and machine safety on the first day of the class.
Page 22

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TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
Page 23
Bilateral Understanding in a Workshop

A. Report
It is necessary to observe punctuality in
the workshop. Teaching staff and
trainees must follow this rule.
Everybody is oriented and concerned
about their responsibilities. Instructor
and trainees must coordinate with each
other during their training inside the
workshop.
Trainees must respect his fellow trainees
and, most of all, his Instructors. They
must submit any requirements on time.
B. Communicate
Communication means exchange of
information between people by means of
speaking or writing. It is very important
for Trainees to learn proper
communications.
The workshop training will prepare the
Trainees to apply proper communications
when they go to their respective jobs in
the plastics industry.
C. Talk
The Trainees will be facing many tasks
in their future jobs which would require
them to talk and be understood. Inside
the workshop, all Trainees are required
talk using the English language.
Page 24
WORKSHOP ACTIVITY #3—Bilateral Understanding in a Workshop
1. To know the rules and regulations in Workshop #4

2. To learn the safe shop floor practices
PROCEDURE
PART I—Pipe Extrusion Workshop Rules and Regulations

1. Go around the Pipe Extrusion area in Workshop #4 and read the
posted rules and regulations.
2. Understand the rules and try to memorize them.
3. In your data sheet write the reason each of the rules are necessary.
PART II—General Orientation

1. Tour the workshop with a Senior Instructor while wearing the
prescribed PPE.
2. Listen to what the Instructor explains regarding the machine, utilities
and all equipments inside.
3. Take note what have you observed and learned.
4. Answer all the questions in your data sheet.
Page 25

DATA S H E E T
ACTIVITY #3—Bilateral Understanding in a Workshop
PART I—Pipe Extrusion Workshop Rules and Regulations
RULES AND REGULATIONS IN PIPE EXTRUSION
1.
2.
3.
4.
5.
6.
7.
Page 26

DATA S H E E T
ACTIVITY #3—Bilateral Understanding in a Workshop
PART II—General Orientation

Explain why these things are important inside the workshop.
1. Safety
2. Personal Protective Equipment
3. Reporting to the class
4. Communicating to fellow trainee
5. Studying about the machine
6. Respecting the Instructor
Page 27

WORKSHOP ACTIVITY #3—Bilateral Understanding in a Workshop
___________________________________________________________
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________________________
TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
Page 28
Raw Materials
Plastics pipes are made from different plastics or resin. Each resin has its
properties suitable for use as plastic pipes.
These plastics raw materials differ in their processability, appearance form,

color, and their physical and chemical properties. These are very important
information that must be known before plastics resins are processed into a
plastics pipe.
Main Differences between PVC and HDPE
Description PVC HDPE
Material Form Powder and pellets Pellets
Heat resistance Less (up to 80oC to 110oC) Fairly ( up to 110oC)
Cold resistancce Less Good ( up to - 80oC)
Stiffness High Flexible
Tg, glass transition temp 75oC to 85oC -125oC
Tm, melting temp. n/a 135oC
Shrinkage 1 % - 1.5 % only 2 % - 4%
Processing temp. for pipe 130oC - 180oC 180oC - 230oC
Adhesive, heat sealing and

Adhesion none, heat sealing only
radio frequency sealing
Freezing/ purging material Needed No need
Page 29
WORKSHOP ACTIVITY #4—Raw Materials
Pipe Extrusion Condition
Different plastics have different processing temperature conditions.

HDPE requires a higher temperature than PVC, since PVC contains chlorine
and can decompose or burn when heated beyond 200°C.
Example of processing temperature, °C, using the single screw extruder of
HIPF:
E1 E2 E3 E4 Adapter D1 D2 D3
PVC 170 175 180 180 170 185 190 n/a
HDPE 180 190 200 210 190 210 210 205
Plastics Groups
The plastics are generally grouped into two types: thermoplastics and
thermosets.
• Thermoplastic—refers to a plastic material that softens when heated and

harden again when cooled. This can be done several times.
• Thermoset—refers to a plastic material that softens when heated but stay

only for a short time and then hardens. The main difference with
thermoplastics is that, thermosets cannot be heated and re-heated to
soften it again.
Page 30
1. To review the two main subgroups of plastics

2. To learn the common materials used for plastic pipes
3. To know the difference between PVC and HDPE when processed as
pipes
4. To know the additives for PVC and the use of freezing materials
PROCEDURE
1. Tour the workshop and look at the materials presented by the

instructor.
2. Observe the materials presented in class (use senses like touch).
3. Listen to your instructor as he names the examples of each materials
record on your data sheet.
4. Remember the content of each material tank then write on your data
sheet.
Page 31

DATA S H E E T
ACTIVITY #4—Raw Materials
PART I—Plastic Groups
EXAMPLES OF THERMOPLASTICS
1.
2.
3.
4.
5.
Thermoplastics [ can cannot ] be recycled.
EXAMPLES OF THERMOSETS
1.
2.
3.
Thermosets [ can cannot ] be recycled.
PLASTICS MATERIALS COMMONLY USED FOR PIPES
1.
2.
3.
4.
Page 32

DATA S H E E T
PART II—Raw Material in HIPF for Pipe Processing
1. 2.
Name: ______________________ Name: ______________________
Form: ______________________ Form: ______________________
Color: ______________________ Color: ______________________
3. 4.
Name: ______________________ Name: ______________________
Form: ______________________ Form: ______________________
Color: ______________________ Color: ______________________
Page 33

DATA S H E E T
PART III—Material Used for Cleaning Extruder After PVC Production
1.
Name: ______________________
Form: ______________________
Color: ______________________
PART IV—Additives for PVC
Type of Additive Function
S______________ Prevent thermal degradation of PVC
Prevent degradation caused by light (UV light)

Ultra____________
to PVC
P_______________ Provide flexibility and softness of PVC

Improve mechanical strength, flexural modulus
F_______________
and heat distortion temperature
Make it easy for plastics to slip, to minimize
Lu_____________
frictional heat
I________ M______ Gives PVC higher impact strength
Page 34

DATA S H E E T
PART IV—Storage Tanks Contents
Page 35

I. From the list below, write the material name under its correct
subgroups
Epoxy resin, Polypropylene (PP), Polybutylene(PB),
Melamine resin, Polymethylmethacrylate (PMMA),
Polyvinyl Chloride (PVC), Polyphenol, Polyethelene (PE)
THERMOSETS THERMOPLASTICS
1. ______________________________ 1. ______________________________
2. ______________________________ 2. ______________________________
3. ______________________________ 3. ______________________________
4. ______________________________
5. ______________________________
II. What are these materials? Write the answers in the blanks.
A. B. C.
________________ ________________ ________________
III. HIPF use these materials in pipe extrusion:
1. Po_____________ __________ = PVC
2. Hi___ __________ ______________= HDPE
Page 36

QUESTIONS & EXERCISES … continued
IV. Which material is harder as a pipe?
1. PVC 2. HDPE
V. Which material has a lower processing temperature using our Proton

45?
1. PVC 2. HDPE
VI. Connect each tank to the correct content using a line.
PVC compounds, PVC compounds, PVC compound,

pellets regrinds powder
Page 37

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TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
Page 38
Extruder Machine
• An extruder is a machine intended for extruding a thermoplastic resin.

• Extrusion for pipe processing is the process of heating thermoplastic
resin, making it uniformly soft inside the barrel, mixing and pushing it by
the screw through the die, and finally forming it into a pipe as the final
product form.
• The basic parts of an extruder are: motor, gear, hopper, screw, barrel,
heater, adapter, and die.
Page 39
WORKSHOP ACTIVITY #5—Extruder Machine
1. To be able to know the different basic parts of extruder.

2. To be able to know the functions of each basic parts of extruder.
PROCEDURE
PART I—Basic Parts of the Extruder
1. In your data sheet are pictures of an extruder, and some basic parts.
2. Correctly identify the basic parts of the extruder by writing down the
names of basic parts of extruder on the space provided.
PART II—Functions of Each Basic Part of the Extruder
1. In your data sheet, write down the functions of each of the basic
parts of extruder.
Page 40

DATA S H E E T
ACTIVITY #5—Extruder Machine
PART I—Basic Parts of the Extruder

3.
6.
1. 7.
8.
2.
4. 5.
Page 41

DATA S H E E T
ACTIVITY #5—Extruder Machine
PART II—Functions of Each Basic Part of the Extruder
1. Motor
2. Gear
3. Hopper
4. Screw
5. Barrel
6. Heater
7. Adapter
8. Die
Page 42

Choose the correct answer.

1. What part of extruder drives the screw?
(a) Barrel (c) Main motor
(b) Hopper (d) Screw
2. What part of extruder transmits the torque of the motor to the
extruder screw?
(a) Motor (c) Screw
(b) Gear (d) Die
3. What part of extruder holds and feeds the raw materials into the
extruder barrel?
(a) Hopper (c) Barrel
(b) Screw (d) Gear
4. It is a cylindrical strong metal tube where the material is fed, heated,
melted, mixed and pushed by the screw forward?
(a) Screw (a) Hopper
(b) Adapter (d) Barrel
5. What part of extruder mixes and moves/pushes the molten plastic
forward inside the barrel?
(a) Screw (c) Die
(b) Hopper (d) Adapter
6. What is the part of extruder that is installed around the barrel to give
heat and then melt or soften the resin inside the barrel?
(a) Die (c) Heater
(b) Barrel (d) Adapter
7. What part of extruder connects the barrel and the die?
(a) Die (c) Motor
(b) Adapter (d) Barrel
8. What is the end part of extruder where the pipe is being formed?
(a) Hopper (c) Screw
(b) barrel (d) Die
Page 43

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TRAINEE’S GRADE
FOR THIS ACTIVITY
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Page 44
Vacuum Bath/Cooling Tank
• Vacuum tank is the next stage of the process after leaving the die. It is
where the pipe is formed and cooled.
• At the entrance of the vacuum tank, a calibrator is fixed to control the
size or dimension of the pipe.
• To attain the standard dimension of the pipe which is formed based on
the size of the calibrator, vacuum pump should be activated during
operation.
• The vacuum tank should be filled with cooling/chilled water up to the
desired level (below the haul-off pipe) to cool the pipe.
• Spray pump should be activated during operation to spray the chilled
water around the pipe.
VACUUM
TANK
Page 45
WORKSHOP ACTIVITY #6—Vacuum Bath/Cooling Tank
1. To be able to set-up the vacuum tank for operation.

2. To be able to know the functions of each system or parts of vacuum
tank.
PROCEDURE
PART I—Setup of the Vacuum Tank for Operations
1. Go to your assigned Proton 45 machine and visually inspect the

calibrator before installing it.
2. Fill the vacuum tank with cooling/chilled water up to the desired
level below the haul-off pipe.
3. Check the water spray system if working by pressing the water spray
button.
4. Check the vacuum system if working by pressing the vacuum pump
button.
PART II—Functions of Vacuum Tank Parts
1. In your data sheet, write down the functions of calibrator, water spray
system, vacuum system and chilled water.
Page 46

DATA S H E E T
ACTIVITY #6—Vacuum Bath/Cooling Tank
PART I—Setup of the Vacuum Tank for Operations
Check after the completion of set-up.
No. Parts Yes/No Remarks
1 Calibrator
Cooling Water/
2
Chilled water
3 Water spray system
4 Vacuum system
Water level
Spray pump
Vacuum pump Calibrator
Page 47

DATA S H E E T
ACTIVITY #6—Vacuum Bath/Cooling Tank
PART II—Functions of Vacuum Tank Parts
No. Parts Functions
1 Calibrator
Cooling Water /
2
Chilled water
Water spray
3
system
Vacuum
4
system
Water spray system
Calibrator
Chilled water level
and inlet
Vacuum system
Page 48

1. What system is used to attain the correct size measurement of the

pipe based on the standard?
(a) Vacuum system (c) Chilled water
(b) Water spray system (d) Calibrator
2. What is a sprinkle type system that spray the water around the pipe
inside the vacuum tank?
(a) Chilled water (c) Vacuum system
(b) Water spray system (d) Calibrator
3. What is the system in vacuum tank to make the pipe come in close
contact with the sleeve of calibrator to attain the standard size of the
pipe?
(a) Vacuum system (c) Calibrator
(b) Chilled water (d) Water spray system
4. What is the liquid that cools the pipe inside the vacuum tank?
(a) Calibrator (c) Chilled water
(b) Water spray system (d) Vacuum system
5. What is the down stream equipment next to the die?

(a) Vacuum tank (c) Vacuum system
(b) Calibrator (d) Water spray system
Page 49

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TRAINEE’S GRADE
FOR THIS ACTIVITY
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Page 50
Haul-off Machine /Traction
Plastics pipe extrusion consists of several processes and machines. Each one
is very important to produce a good quality pipe.
One of these equipment is called the traction (haul-off) machine and is

generally called a puller.
This so called puller , pulls the extruded pipe from the die at a constant rate.
The pulling speed must be constant so the wall thickness remains the same al
through out the pipe.
The type of puller in HIPF is

called BELT puller
Description of the HIPF Haul-off Machines in Workshop 4
• 2 belt haul off with 2 servomotors

• Pipe Size = up to 63 mm outside diameter
• Speed = 0.1—60 m/min
• Belt width = 80 mm
• Belt length = 850 mm
• Operating air pressure, Supply = 5 bars
Page 51
WORKSHOP ACTIVITY #7—Haul-off Machine /Traction
IMPORTANT FACTORS
AIR PRESSURE
Air pressure—the pneumatic forces make the belt get in contact with the
pipe.
BELT MOTION
The belt rotates towards each other and in opposite direction so that the
pipe is pulled .
PULLING SPEED
The pulling speed is the speed at which the haul-off pulls the pipe. It is
measured in “ m/ min”.
If the speed is too fast it may cause the pipe to be cut or torn at the die
part.
If it is too slow, it may cause the pipe to sag and block the calibrator.
CLAMPING PRESSURE
Clamping pressure—the force at which the belt or roller makes contact

with the pipe. This is possible because of the air pressure.
If the force is too high it can cause a deformed or non– circular pipe.
If it is too low, it may have loose contact with the pipe that may cause the
pipe to slip. This will then lead to a blocked calibrator.
Page 52
1. To learn the use and importance of the puller in pipe processing

2. To learn functions of major parts of the haul-off machine
PROCEDURE
1. Go to an energized and linked traction unit as assigned by your

instructor.
2. Identify the name and functions of important parts as your instructor
explains. Record the name on the data sheet.
3. Record your observations and answers on the data sheet
4. Do as the instruction says on this workbook regarding the following:
PART I—Parts and Functions of the Machine

PART II—Air Pressure
PART II—Belt Motion
PART IV—Pulling Speed
PART V—Clamping Pressure
Page 53

DATA S H E E T
ACTIVITY #7—Haul-off Machine /Traction
PART I—Parts and Functions of the Machine
• Other names for traction (haul off) machines are:
1. P__ __ __ __ __
2. TAKE - __ __ __ SYSTEMS
• Common types of these are
1. R __ __ __ PULLERS
2. BELT PULLERS
3. CATERPILLAR P __ __ __ __ __
• Name the major parts of the machine
1.
2.
3. 4.
Page 54

DATA S H E E T
PART II—Air Pressure
1. Go to the supply air regulator at the side.

2. Look at the initial position of the upper belt.
3. Rotate the adjustment knob to the right. See picture
What direction did the upper belt go?
up
down
4. Now put it to 0 bar value by rotating the knob to the left.
What direction did the upper belt go?
up
down
5. Adjust the knob again to put

air pressure. This time set it to
the middle. What is the value
at the middle?
_____ bars or ____ psi
6. Write all pressure readings in

bars on the drawing at the
right. Bars
Page 55

DATA S H E E T
6. Now check or set the Pressure for the upper belt.
Backpressure rear = 1 bar Main pressure= 2 bars Backpressure front = 1 bar
PART III—Belt Motion
1. Put the “Reference value from” to HAUL OFF

2. Press the Motor Starts button.
What happens to the belt?
Belt rotates Belt stops
3. Press the Motor Stop button.

What happens to the belt?
Belt rotates Belt stops
4. Press the Motor Start again

5. Look at the direction the upper belt and lower belt rotates.
6. Which belts rotates the direction drawn below?
7. Keep the Motor rotation for our next activity.
______________ belt ______________ belt
Page 56

DATA S H E E T
PART IV—Pulling Speed
1. Look at the initial speed in the indicator.
HAUL OFF FASTER
HAUL OFF SLOWER
2. Press Haul off faster button for 5 seconds. What happens to the
speed?
START SPEED = m/min
END SPEED = m/min
3. Press Haul off slower button for 10 seconds. What happens to the
speed?
START SPEED = m/min
END SPEED = m/min
4. Switch the Reference value to EXTRUDER.

Is the speed same as the End “ m/ min” in step 3?
YES NO
Page 57

DATA S H E E T
PART V—Clamping Pressure
Track Release
Track Squeeze
1. Press the Track Squeeze button. What happens to the upper belt?
2. Press the Track Release button. What happens to the upper belt?
3. Put the “Reference Value from” switch to EXTRUDER, then press

Track Squeeze.
Did the upper belt moved down?
YES NO
4. Put the “Reference Value from” switch to HAUL OFF, then press
Track Release.
Did the upper belt moved up?
YES NO
Page 58


I. Give two other names for traction?
1. ________________________
2. ________________________
II. Multiple choice
1. The upper belt in our traction goes ______________ when we press

the Track Squeeze button.
a. right c. left
b. up d. down
2. The supply air pressure at the side of the traction is set to

a. 6 bars. b. 2 bars.
c. 10 bars. d. 5 bars.
3. The rotation of the belt ___________ when we press Haul Off

Faster button.
a. becomes slower b. becomes faster
c. stop s d. do not change
4. If the haul off speed is too fast,

a. the pipe being pulled becomes flat.
b. the pipe being pulled may tear at the die side.
c. there would be no change in the quality.
5. If the clamping pressure or contact on the pipe being pulled is too

high,
a. the pipe being pulled becomes flat.
b. the pipe being pulled may tear at the die side.
c. there would be no change in the quality.
III. True of False.
Write T if you think the sentence is true and F if false.

_____ 1. The traction is usually positioned after the vacuum bath.
_____ 2. The traction is not important to pipe production and quality.
_____ 3. Puller is another name for traction.
_____ 4. The speed of the belt rotation is set using the button “Motor Stop”.
_____ 5. The pipe may deform if the clamping pressure is too high.
Page 59

IV. Name the parts and draw.
1. Put the names of the parts in the space provided.
A. __________________________ B. __________________________
C. __________________________ D. __________________________
2. Draw the symbol of the traction found in the operating panel of our
single screw extruder.
Page 60

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
Page 61
Cutting Saw
Cutting saw cuts the processed pipe to a specified lengths (3 m to 6 m).
When the end of the pipe reaches a specified position, a limit switch
activates. This causes the machine to grip the pipe, then the cutting saw cuts
the pipe. After the pipe is cut, the unit moves back to the original position.
Circular saws are often used to cut the rigid pipes. Cutting saws need to be
fast to avoid bur and to provide clean cut surface, as well as good
dimensional accuracy.
The cutting saw unit consists of

1. Operating panel,
2. Cutting saw with shield,
3. Electrical motor,
4. Carriage speed adjustment,
5. Cutting speed adjustment, and
6. Pressure gauge.
Main Parts of Cutting Saw
• Cutting saw—it is a circular saw which cuts the processed pipe with
clean cut surface.
• Carriage unit—this system grips the pipe and moves forward according
to the cutting speed. When the pipe is cut then it moves back to its
original position.
Cutting Speed
It is very important that the cutting saw speed should be fast, otherwise the
cutting surface of the pipe will have burs. You get a clean cut surface when
the cutting speed is very fast.
Page 62
WORKSHOP ACTIVITY #8—Cutting Saw
THEORETICAL BACKGROUND … continued
Cutting Saw with Shield
Electric Motor Operating Panel
Carriage Unit
Cutting Speed
Pressure Gauge
Carriage Speed
Page 63
OBJECTIVE OF THE ACTIVITY
1. To learn the names and parts of the cutting unit.
PROCEDURE
PART I—Parts of the Cutting Unit
1. Go to the Workshop floor and observe the Cutting Saw machine

assigned to you by your Instructor.
2. Using the data sheet in the following page, correctly list down the
names and parts of the cutting saw.
3. Look at the operating panel of cutting saw try to remember the parts
of the cutting saw. In your data sheet, write down the names of the
parts.
PART II—Three (3) Main Parts of the Cutting Saw
1. In your data sheet, identify the three main parts of the cuttings saw
and give their respective functions.
Page 64

DATA S H E E T
ACTIVITY #8—Cutting Saw
PART I—Parts of the Cutting Unit
THE CARRIAGE UNIT
1.
2.
Page 65

DATA S H E E T
PART I—Parts of the Cutting Unit … continued
THE PRESSURE UNIT

1.
2.
3.
4.
5.
6.
Page 66

DATA S H E E T
PART I—Parts of the Cutting Unit … continued
THE OPERATING PANEL

1.
2.
3.
4.
5.
6.
7.
Page 67

DATA S H E E T
PART II—Three (3) Main Parts of the Cutting Saw
3 Identify and name & the parts of cutting saw
1.
2.
3.
Functions of the 3 main parts
1.
2.
3.
Page 68


I. Choose the correct answer.
1. Role of cutting saw in pipe processing.

(a.) to cut the processed pipe (c.) pull the pipe
(b.) size the pipe (d.) none of the above
2. How is the cutting saw working?

(a.) by electrical motor (c.) manually
(b.) both (d.) none of the above
3. Which is a part of the cutting saw?

(a.) calibrator (c.) die
(b.) circular saw (d.) none of the above
4. Can you identify the length of the pipe in HIPF?

(a.) 4M (c.) 3M
(b.) 5M (d.) 1M
5. What is the role of carriage unit in cutting system?

(a.) hold the pipe (c.) cut the pipe
(b.) push the pipe (d.) none of the above
II. True or False
1. Cutting saw needs lubricating oil for lubrication of parts. ( )
2. We can’t adjust the cutting saw speed. ( )
3. Our cutting saw cuts 6 meters length pipe. ( )
Page 69

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
Page 70
Tipping Table
Tipping table is a mechanism which transfer the 3-meter pipes which were
cut by the cutting saw to the push cart by activating the tipping mechanism
with the help of sensors.
This tipping table has two sensors.

1. One sensor sends signals to cutting saw to cut the pipe.
2. One sensor gives the signal to transfer the pipe from tipping table to
push cart.
Tipping Table
Page 71
WORKSHOP ACTIVITY #9—Tipping Table
Sensor 2 Table Sensor 1
Operating Panel Motor
Sensor Motor
Page 72
1. To learn about tipping table.

2. To identify the five(5) main parts of the tipping table.
PROCEDURE
1. Go to the Workshop floor and observe the tipping table assigned to

you by your Instructor.
2. Using the data sheet in the following page, correctly list down the
parts of the tipping table.
Page 73

DATA S H E E T
ACTIVITY #9—Tipping Table
Five (5) Main Parts of the Tipping Table
2.
5.
1.
4.
3.
Functions of the Main Parts of the Tipping Table
1.
2.
3.
4.
5.
Page 74


I. How many sensors are there in the tipping table?
a. 3
b. 2
c. 1
d. 4
II. Give the 5 parts of tipping table
1. ___________________________________
2. ___________________________________
3. ___________________________________
4. ___________________________________
5. ___________________________________
III. True or false
1. Tipping Table works by sensors. ( )
2. Sensors cuts the processed pipe. ( )
3. Tipping table having 2 sensors. ( )
Page 75

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
Page 76
Computer Control
The Extruder Personal Computer (PC) is the “heart and soul” of plastic pipe
extrusion process. It is where the commands for the machine operations
come from, and where the operational parameters are stored for execution. It
replaces the conventional method of operations during the early stages of
development of the technology. The rapid growth of computerization made
the operations of a plastics pipe extrusion machine much easier. Basic
knowledge in computer is required to perform this activity.
The PC controls the following:

1. Die zone temperatures
2. Extruder barrel zone temperatures
3. Screw speed
4. Traction
5. Main motor
Page 77
WORKSHOP ACTIVITY #10—Computer Control
The Control Station Assembly and the Control Panel

10.4” TFT color
Flashing light display (optional
touch screen)
24 V DC fan and
outlet filter
(sealed cooling 68 key mem-
system inside) brane keypad
(16 with LED)
Emergency
stop button
Key operated
switch for the
emergency
travel circuit
Illuminated push button

(acknowledgement of
emergency stop relay
and for displaying the The Interface Panel consists of :
24 V DC control voltage)
• 2x robust and dust proof
covers which can be locked
Interface or unlocked by pressing the
Panel push button
• 1x parallel printer interface
• 2x USB interfaces
• 1x PS2 keyboard interface
(5 V fuse)
• 1x Ethernet RJ45 interface
• 1x 3.5” floppy disk drive
(1.44MB)
back view
Page 78
The Keypad of the Control Panel
1 2
4 3
6 5
8
7
10
11
12
14
13
9
1. PRINTER key—print a hard copy of a screen

2. NEXT PAGE key—switch between the current screen and the screen
displayed last
3. MENU key—currently available screen will be displayed
4. BACKWARD and FORWARD keys—“extend” and/or “retract” a
corrugated pipe sequence
5. OPEN and CLOSE keys—for opening and closing the clamping jaws of
the puller
6. DRIVE keys—for starting a drive and for pre-selecting a speed
adjustment
7. ON key (green) and OFF key (red)
8. SYNCHRONOUS key—either to start the entire line or to carry out a
speed modification for the entire line
9. NUMERIC keys
Page 79
10. DELETE key—either deletes the numerical entry that was just entered
but has not yet been confirmed by pressing “ ENTER”, or cancels a
sequence that is not to be carried out for one reason or another.
11. PAGE keys—for scrolling backwards and forwards through the
individual “Main Screens”, and scrolling up and down within a single
“Main Screen” when sub-pages are present
12. CURSOR keys—move the screen cursor
13. ENTER key—press after an entry to pass the value to the EXc PRO-XP
control; also used to switch the screen key from ON to OFF or back
again
14. SHIFT key—activates additional functions
Page 80
1. To become familiar with the names and functions of each part of the
extruder PC
2. To learn how to operate an extruder PC in order to control the
parameters in performing the Plastic Pipe Extrusion manufacturing
process
PROCEDURE
1. Go to your assigned machine and switch on the main power supply.

2. Familiarize yourself with parts and functions of the control panel.
3. In your data sheet, correctly identify the parts of the
Part I—Control Station Assembly
Part II—Control Panel
Page 81

DATA S H E E T
ACTIVITY #10—Computer Control
Part I—Identify the parts of the Control Station Assembly
At the back of the Control Station

3
1. 5.
2. 6.
3. 7.
4. 8.
Page 82

DATA S H E E T
ACTIVITY #10—Computer Control
Part II—Identify the keys in the Control Panel
5 6
7
4
10
3
1
2
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
Page 83


1. Which key is used for switching between the current screen and the
screen displayed last?
a. Next page key
b. Printer key
c. Menu key
d. Printer key
2. Which key is used either to start the entire line or to carry out a speed
modification for the entire line and it works in the same way as the
drive keys?
a. Synchronous key
b. ON key
c. Open key
d. Forward key
3. Which key when pressed will display along the top of the screen a
menu bar showing all the currently available screens?
a. Open key
b. Printer key
c. ON key
d. Menu key
4. Which key can be used to print a hard copy of a screen?

a. Menu key
b. Printer key
c. Synchronous key
d. F3 key
5. Which keys are used to extend and/or retract a corrugated pipe

sequence?
a. Backward and Forward keys
b. ON and OFF keys
c. Open and Close keys
d. Drive and Synchronous Keys
Page 84

6. Which keys are used for opening and closing the clamping jaws of the
puller?
b. ON and OFF keys
d. Drive and Synchronous keys
7. Which keys are used in conjunction with the drive and the synchronous
keys?
b. ON and OFF keys
d. Drive and Synchronous keys
8. Which keys are used if the cursor is located on a light blue parameters
field where a numerical entry can be made?
a. Numeral keys
b. Cursor keys
c. Page keys
d. ON and OFF keys
9. Which key is used either to delete the numerical entry that was just
entered but has not been confirmed by pressing enter key, or to cancel a
sequence that is not to be carried out for one reason or another?
a. Delete key
b. Backward key
c. OFF key
d. Close key
10. Which keys move the screen cursor?

a. Cursor key
b. Delete key
c. Backspace key
d. Synchronous key
Page 85

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
Page 86
Mock Operation
During actual operation of the Pipe Extrusion plant, the following forms are
used:
1. Job Order (Form # J01)—The schedule or size to be run in the

machine.
2. Raw Material Requisition and Issuance Slip (Form # M01)—For
preparing the materials.
3. Daily Production Report (Form # PR01)—The total quantity of the
production (good & rejected) and the performance of the trainees and
the machine.
4. Pipes Inspection (Form # QC01)—To check the quality of the pipes
produced.
5. Parameter Chart (Form # MP01)—To monitor all parameter and zone
temperatures.
6. Setup Parameter Chart (Form # SP01)—To guide or set the parameter
in the machine.
Standard Operating Procedure Pipe Extrusion
1. Utility preparation:
a. Switch On the main electric power supply (By maintenance).
b. Switch On the close system chiller (By maintenance).
c. Switch On the air compressor.
d. Switch On the water pumps and open system chiller.
Page 87
WORKSHOP ACTIVITY #11—Mock Operation
SOP for Pipe Extrusion… continued
2. Material preparation:
a. Withdraw materials using withdrawal slip from storage signed by
responsible person.
* HDPE/PVC compound pellets—Make sure hopper is clean and
in close position. Then place material into the hopper.
* Purging or freezing material—Put the purge material near the
hopper and wait for the machine to be ready for purging.
3. Machine preparation, heating the barrel & die:

a. Switch On the main switch in the Extruder panel.
Notes:
* Don't touch any key on the operator's panel when the computer
is setting-up.
a.* Check all electrical connections on barrel and die, like:
thermocouple, pressure sensor, melt pressure, electrical wirings,
etc.
b. Set the purge temperature at 140°C and normal temperature in all
heating zones. Then activate the 1st or purge temperature.
* Normal temperature: PVC about 170 – 195°C.
HDPE about 190 – 230°C.
c. Switch On the respective zone heaters needed and then the Master
heater.
d. Open the machine cooling water supply (to protect the gasket of
feeding zone & to cool inside the control panel).
e. Switch On the power of down stream equipment (vacuum bath,
traction, saw & tipping table).
f. Press illuminated key “S/H0”
* Light is flushing on the operators panel.
– Switch-off the light flushing by pressing the "cancel" key in the
operators panel.
– Remove the "alarm" in the alarm list in operators panel.
Page 88
g. Confirm the operating condition of downstream equipment.

* Traction—Test the speed and clamping operation.
* Saw—Test the cutting and carriage operation.
* Tipping table—Test the tip-off operation and then switch-off.
* Vacuum bath—Insert the haul-off and filled the vacuum tank
with water up to the desired level below the haul-off. Then test
the water spray and vacuum pump operation. Everything ok, stop
the pump and close the water supply.
4. Switch the PURGE temperature to NORMAL temperature.

a. When the Purge temperature is stable (not less than 1 hour from
the start of heating), switch to Normal temperature. (Follow the
Parameter chart form.)
Note: * As soon as the Normal Temperature reached the Set
Point, start purging the extruder barrel & die immediately.
5. Start up safety precautions:

a. Operate the machine only if all protective and safety devices such
as removable safety devices, emergency shut-off equipment and
others are in place and fully functional.
b. Before starting up or setting the machine in motion, make sure
that no body can be put at risk.
Start up conditions
1.) Downstream equipment must be ready for operation.
2.) Heaters must reached the normal temperatures.
3.) The barrel flange plate and heater bands must be tightly fixed.
4.) Screw engaged
5.) ALARM (screen 44) no (significant) alarm messages.
6.) FAULTS (screen 43) no (significant) fault messages.
6. Purging/cleaning the barrel and die for PVC

Note: *No Purging with freezing material for HDPE.
a. Set the scroll box under the die.
b. Switch On the main motor at Zero rpm.
c. Run the extruder screw about 3 – 5 rpm for initial start.
d. Input purging material into the feeding zone manually.
Page 89
e. Increase the screw rpm gradually by 2rpm up to about 15 - 20

rpm.
f. Confirm that the freezing material coming out from the die is
clean/pure.
g. Stop filling of freezing material and then close the freezing
material port.
h. Set the hopper into the opening of feeding zone to feed PVC/
HDPE material then lock the pin.
i. Confirm that the PVC material coming out from the die is pure.
j. Take out the scroll box under the die.
k. Pre-set to synchronization (Example: Screw = 20 rpm and
Traction = 0.5 rpm). Then position your cursor in the
synchronization in increasing the speed.
7. Check the uniformity of thickness
a. Check the molten pipe coming out from the die if the thickness is
uniform.
* Cut off the molten pipe coming out from the die using a spatula.
* Centering is correct when the pipe emerges for a short time in
parallel with the extrusion axis prior to folding down by the force
of gravity.
8. Run downstream equipment

a. Move the vacuum tank closer to the die with the haul–off for
operational position.
b. Clamp the haul-off in the traction.
c. Run the water spray pump of cooling bath.
Note: * When the spray pump is not running the water supply must
be closed and when it is running the water supply must be open.
9. Connect the molten pipe into the haul–Off pipe

a. For PVC: Connect the molten pipe into the haul-off pipe and tie –
up the rope into the molten pipe which is connected to the haul-
off pipe.
b. For HDPE: Connect the molten pipe directly into the haul–off
pipe with out the rope.
Page 90
10. Run the haul–off:

a. Run the haul–off. Increase the speed by synchronization.
b. Move the vacuum tank closer to the die.
Note: * Wait until the haul–off pipe pass through the vacuum
tank with the new pipe formed then run the vacuum pump.
11. Run the vacuum:

a. Run the vacuum pump and set the pressure to about not less than
–2 bars for PVC and not less than –4 bars for HDPE.
12. Run the saw:

a. Wait until the haul–off go beyond the saw and remove the haul-
off pipe.
b. Cut the bad pipe manually.
c. Run the saw and make sure that the limit switch is active to cut
the good pipe automatically.
d. Switch-on the tipping table.
13. Increase the speed:

a. Increase the speed gradually by 1 or 2 rpm until you attain the
desired setting. (Example: 60rpm)
14. Check the quality of pipe produced / Q.C.:

a. Check the quality of pipe like: O.D., I.D., uniform thickness,
smoothness, etc.
b. Identify the defect and adjust to get a good quality pipe.
c. Get pipe samples for Q.C. to check the quality of pipe based on
the standard. (Example: Pipe = 30 cm in length)
15. Production continue until completed:

a. The machine is now producing the pipe.
b. Monitor the machine parameters, material feeding and all parts of
the machine periodically to maintain the good running condition.
(Example: Every 3 or 5 min.)
Page 91
16. Stop the production:

a. Move the hopper into a close position.
b. Confirm that the pressure inside the barrel is decreasing. (See
operator's panel).
c. Slow down the extruder screw by 5 rpm until about 20 - 30rpm.
d. For PVC: Check the feeding zone if empty and then input
freezing material.
e. For HDPE: No need for freezing material.
17. Retract the vacuum bath:

a. Move the vacuum tank away from the die.
b. Cut the molten pipe using spatula.
18. Stop down stream equipment:

a. Stop the traction.
b. Stop the vacuum pump and spray pump.
c. Close the inlet and open the outlet of cooling water.
d. Stop the saw.
19. Cleaning/purging of barrel and die:

a. Input purge material into the feeding zone manually.
b. Wait for the purge material to start coming out from the die, then
switch the normal temperature to purge temperature.
c. Confirm that the purging material coming out from the die is
pure.
d. Stop filling of purge material into the feeding zone & wait until
the barrel is empty. (Barrel is empty when no more material is
coming out from the die).
Page 92
20. Switch-off the Machine:

a. Slow down the screw rpm to about 5–10 rpm.
b. Switch Off the Main motor.
c. Switch Off the respective heater zones.
d. Switch Off the master heater.
e. Switch Off all downstream equipment (vacuum bath, traction,
saw and tipping table).
f. Shut down the computer/operator's panel – wait until the massage
"the computer is now ready to switch-off".
g. Switch Off the main power in the extruder panel.
h. Close the cooling water supply of the machine.
2. Switch Off air, water and electricity:

a. Switch Off air compressor.
b. Switch Off open system chiller.
c. Switch Off all water pumps.
d. Switch Off main power supply extruder (by maintenance).
e. Switch Off close system chiller (by maintenance).
Page 93
1. To be able to experience a real Pipe Extrusion plant operation

2. To be able to gain knowledge and confidence in actual operation
PROCEDURE
1. Go to your assigned Proton 45 Machine.

2. Check the Job Order.
3. Follow the Standard Operating Procedures (SOP) to run the machine.
4. Monitor your production run by filling up the required forms during the
operation.
Page 94

DATA S H E E T
ACTIVITY #11—Mock Operation
Page 95

DATA S H E E T
Page 96

DATA S H E E T
Page 97

DATA S H E E T
Page 98

DATA S H E E T
Page 99

DATA S H E E T
Page 100

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
________________________
TRAINEE’S GRADE
FOR THIS ACTIVITY
________________________
Page 101
Glossary of technical terms for Pipe Extrusion
Barrel Part of an extruder machine that houses the screw

and where the heating takes place
Barrel cooling fan An electric motor fan that cools the barrel when
the temperature exceeded its desired setting
Calibrator A piece of hollow metal attached at the entrance of
the vacuum bath where the extrudate coming from
the die passes through to form and stabilize the
pipe's desired shape
Clamping screw A piece of metal which do the clamping of the
pipe during cutting process
Cutting saw Equipment that cuts the extruded pipe into the
desired length
Die A device in an extruder machine where the molten
plastic passes through to form it into the desired
shape
Dust separator An cloth shaped like a balloon that is used to
collect dust during grinding process
Emergency stop switch A push button switch to deactivate a moving
equipment; Used to bring the machine or
equipment to a halt when a dangerous condition
arises
Extrudate Soft plastics material coming out of the die
Extruder An equipment that forces soften plastics through
an opening that would give the desired shape
Extruder main motor The main motor of Extruder machine which drives
the extruder screw with the aid of a reduction gear
box assembly
Extruder water cooling system A water cooling system that regulates the
temperature of the extruder machine
First (1 ) Temperature Setting Refers to the 1st stage temperature setting
st
@140°C to stabilize the amount of heat in all

zones without burning the purging or cleaning
material.
Freezing compound A cleaning material for the screw and barrel, most
commonly comes in a powder form and suited for
a low temperature setting, like 140°C
Gear oil sight glass Part of the reduction gear box where we can see
(Continued on page 103)
Page 102
(Continued from page 102)
the level of lubricating oil for the gear train

assembly
Granulator or crusher machine An equipment used for crushing or grinding
plastics pipes for recycling
Granule cooler A hopper-like tank where the produced pellets are
further cooled using water cooling jacket before
the pellets go to the vibrating screen
Haul-off pipe A long pipe used during start up that extends from
the tip of the vacuum bath up to the exit point of
cutting saw near the tipping table
Heater band An accessory that is wrapped around a die or a
barrel and acts as a heating element supply the
initial heating of the polymer
Heating zones Parts of the die and barrel where heating process
takes place
High Density Polyethylene (HDPE) A crystalline type
thermoplastic material suited for making pipes by
extrusion process
Jumbo Bag Station The final stage in the Pelletizing process, where
the produced pellets are collected prior to storage
Material hopper Integral part of extruder machine that holds the
raw material
Material vacuum conveying pump An equipment driven by an electric
motor to suck raw material from its original bin to
the material hopper by vacuum
Material vacuum vent Part of extruder machine along the barrel line
where you can find an opening for material
cleaning by vacuum
Mechanical centering bolt A metal threaded bolt located within die
assembly used for centering the extrudate to
produce an even and uniform wall thickness for
the pipe
Melt pressure sensor A piece of detector that determines the pressure of
molten plastic inside the extruder barrel
Metal separator An accessory to crusher machine that collects
unwanted metal that may damage the machine
Operator's panel board The Operator's control panel board where the
parameter setting, monitoring and adjustments are
Page 103
made
Parameter setting List of data that is used as basis in setting-up the
machine to control appropriate condition.
Pelletizer blade A series of metal pieces fitted in the pelletizer
motor used to cut the extrudate into a desired pellet
form
Pelletizing head Part of palletizing machine that cuts the pellets
into its required sizes
Polyvinyl Chloride (PVC) An amorphous thermoplastic material
suited for making pipes by extrusion process
Pre-heat setting A heating up settting option in extruder PC
(personal computer) that allows to heat the
extruder assembly in the future days ahead in
unattended option.
Reduction gear box Part of extruder machine that houses the
gear train assembly that regulates the speed of
extruder screw
Saw Carriage Speed control An adjustment knob to set the speed of the
saw carriage movement
Saw Cutting Speed control An adjustment knob located in the cutting
saw equipment to set the cutting speed
Saw Forward Speed control An adjustment knob located in the Cutting
saw equipment to set the appropriate saw forward
motion.
Screw Part of extruder machine that rotates to
homogenize raw materials for extrusion
Screw percentage load The degree of material loading expressed in
Percentage (%) that is displayed in the control
panel
Screw rpm or screw speed The constant rotational speed of the
extruder screw expressed in revolution per minute
or rpm
Second (2 ) Temperature Setting Refers to the 2nd stage temperature
nd
setting for a certain plastic to operate the extruder

machine.
Synchronous Speed Button The button in the operator’s panel to
control the speed of the extruder screw, with the
haul-off speed automatically synchronizing with
Page 104
extruder screw speed.

Temperature setting The setting of the machine to deliver the needed
amount of heat for good pipe processing, usually
expressed in °C
Thermocouple A device used for measuring temperature
Thermocouple holder An accessory to hold the thermocouple in place
Tipping table An equipment that tips the cut pipes off to the pipe
trolley
Tipping table cutting sensor An electronic sensor, located just right after
the cutting saw, that gives signal to the saw to cut
the pipe at the desired length
Tipping table tipping sensor An electronic sensor located at the further
end of the tipping table that gives signal to the
tipping table control to tip the pipe off to the pipe
trolley
Torque value The tightening value needed to tighten a bolt in die
and extruder assembly expressed in Newton-meter
Traction or Haul-Off Equipment that pulls the pipe at a constant speed
Traction release button The push button in the traction control to
hydraulically lift the upper caterpillar belt away
from mating lower caterpillar belt.
Traction speed The constant pulling speed of the traction
equipment to pull the pipe expressed in meters per
minute
Traction squeeze button The push button knob in the traction control to
hydraulically mate the upper caterpillar belt to the
lower caterpillar belt in order to pull the pipe
Traverse motor The motor that drives the vacuum or cooling bath
closer and away from the die during operation.
Vacuum bath or Cooling bath Equipment where the extruded plastic
(extrudate) material is cooled and stabilized into its
desired shape right after it comes out from the die
Vacuum pressure gauge An instrument to determine the degree of vacuum
pressure
Vacuum pump An equipment driven by an electric motor to create
vacuum pressure
Vibrating screen A conveying equipment with a screen that delivers
the produced pellets with a vibrating motion to the
Page 105
jumbo bag station

Water spray circulating pump An equipment driven by an electric motor
to spray cooling water inside the vacuum or
cooling bath
Page 106
REFERENCES
1. Cincinnati CD manual
2. CT-2-2 Plastics Materials I: Types and Properties of Major Plastics
Materials, Version 3, SPDC Ltd.
3. CT-1-6 Introduction to Plastics Fabrication Technology, Version 3,
SPDC Ltd.
Page 107

Pipe Extrusion Workbook

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Pipe Extrusion Workbook

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Higher Institute for Plastics Fabrication

Pipe Extrusion Department

1st Edition 2009

In its program to continuously improve the quality of instructions at the

General Safety Guidelines … … … … … … … … … … … … … ... 6

Grades Summary Sheet … … … … … … … … … … … … … … ... 7

Activity 1—Safety in the Workshop … … … … … … … … … … .. 8

Activity 2—Workshop Environment … … … … … … … … … … .. 18

Activity 3—Bilateral Understanding in a Workshop … … … … … . 24

Activity 4—Raw Materials … … … … … … … … … … … … … .. 29

Activity 5—Extruder Machine … … … … … … … … … … … … . 39

Activity 6—Vacuum Bath/Cooling Tank … … … … … … … … … 45

Activity 7—Haul-off Machine /Traction … … … … … … … … … . 51

Activity 8—Cutting Saw … … … … … … … … … … … … … … . 62

Activity 9—Tipping Table … … … … … … … … … … … … … .. 71

Activity 10—Computer Control … … … … … … … … … … … … 77

Activity 11—Mock Operation … … … … … … … … … … … … .. 87

References … … … … … … … … … … … … … … … … … … ... 107

To produce competent operators for the industry, the theoretical training

1. Better understand the importance of safety in pipe extrusion

GENERAL SAFETY GUIDELINES

1. Above all, always observe Good Manners and Right Conduct

GRADES SUMMARY SHEET

Activity 1—Safety in the Workshop

Activity 2—Workshop Environment

Activity 3—Bilateral Understanding in a Workshop

Activity 4—Raw Materials

Activity 5—Extruder Machine

Activity 6—Vacuum Bath/Cooling Tank

Activity 7—Haul-off Machine /Traction

Activity 8—Cutting Saw

Activity 9—Tipping Table

Activity 10—Computer Control

Activity 11—Mock Operation

Safety in the Workshop

Before we proceed with our various activities in the workshop, it is highly

PERSONAL PROTECTIVE EQUIPMENT

Why do we have to use Personal Protective

WORKSHOP ACTIVITY #1—Safety in the Workshop

Theoretical Background … continued

A. Wear Work Clothes or Uniform

B. Wear Safety Shoes

C. Wear Appropriate Hand Gloves

HIGH TEMP WORKING

D. Wear Eye Goggles

WORKSHOP ACTIVITY #1—Safety in the Workshop

Theoretical Background … continued

E. Wear Ear Protection

Protect your hearing

F. Wear Head Protection Cap (Hard Hat)

Protect your head with a hard hat when

G. Wear Face Mask

WORKSHOP ACTIVITY #1—Safety in the Workshop

OBJECTIVES OF THE ACTIVITY

1. To be able to identify the hazardous areas in the workshop

Cut Report Form and Submit to Instructor

Part I—Identify the Safety Signs and Symbols

2. Back of Extruder Machine

4. Die Head Assembly

Cut Report Form and Submit to Instructor

Part I—Identify the Safety Signs and Symbols … continued

Cut Report Form and Submit to Instructor

Part I—Identify the Safety Signs and Symbols … continued

10. Inside Cutting Saw Enclosure