Coating extrusion die helix II

for extrusionfor plastic pipesmulti-layer

Overview
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. The unique VSI dies feature a patented 2-step distribution concept consisting of a spiral mandrel for preliminary distribution and a lattice basket (screen basket) distributor for final melt distribution, enabling high throughput rates with compact die dimensions. Modular coating dies are included for a wide range of coating applications.

Summary
Customized mono- and multi-layer tooling for a wide range of customer requirements. The helix II series offers mono- and multi-layer PO pipe toolings configurable to many application requirements and can be adapted to customer-specific needs. The platform supports pipe diameters from microducts (from ~5 mm) up to very large diameters (projects exceeding 2 m) and includes solutions for coating and bundle geometries.

Your Advantages (key benefits)

• Modular expansion for multilayer applications
• Reduced energy consumption
• Easy retrofit solutions for existing extrusion lines
• Excellent homogenization
• Wide processing window
• Large range of applicable pipe diameters
• Consistent, reliable product quality for all pipe dimensions
• Precise wall thickness distribution and raw material savings
• Low pressure loss
• Modular design
• High throughput

Core Offerings

• Patented 2-step distributor concept: spiral mandrel (preliminary distribution) + screen basket distributor (fine/final distribution)
• Reduced gloss streak formation via gentle melt distribution
• Compact design for easier handling and assembly
• Small distribution volume shortens color change times
• Easy cleaning and maintenance due to separate distribution systems per layer

Intelligent process optimization systems (table)
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 ICA with a 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 spiral mandrel, radial or side-fed distributors as required. The optimal distribution concept is selected by material and application.

Your advantages:

• Ideal distribution concept per material
• Minimal servicing and cleaning expense due to strategically positioned parting lines
• Long tooling service life
• Application-specific coatings for wear protection, improved flow behaviour and surface sealing

Our offer:

• Top-quality distribution of functional layers across circumference for raw material saving
• Mechanically and thermally homogeneous melt distribution
• Minimal residence time for materials sensitive to cross-linking or thermal degradation (e.g. PEX-b, EVOH)

Melt distribution concepts available:

• VSI
• Spiral mandrel distributors
• Side-fed distributors
• Spider-type mandrel pipe heads
• Simple, compact radial distributors

EAC – Efficient Air Cooling (Internal Pipe Cooling for VSI-T Toolings)
The EAC internal pipe cooling system adds internal air cooling against the extrusion direction to improve throughput and geometry.

Your advantages:

• Reduces required cooling length by 30%–50% (or alternatively increases throughput)
• Improves pipe roundness
• Energy savings by using exhaust air, e.g. for pre-heating granulates
• Simple retrofit to existing VSI toolings

Our offer:

• Proven EAC system for pipe diameters from 63 mm up to 3,000 mm and wall thicknesses up to 120 mm
• Very powerful ventilators with speed control via frequency inverter
• Sound-insulated ventilator (max. 85 dBA at 1 m)
• Permanently installed exhaust air system with thermal insulation
• Integrated air filter as standard

OPTIMELT – Active Melt Cooling for Thick-Wall Pipe Extrusion
OPTIMELT actively reduces melt temperature before the die head to minimize sagging, improve pipe geometry and enable higher throughput while reducing cooling length and raw material consumption.

Your advantages:

• Reduced sagging
• Lower ovality
• Improved thermal homogeneity
• Higher productivity
• Enables production of pipe wall thicknesses above 100 mm
• Independent from EAC and retrofit available

FDC – Fast Dimension Change with Adjustable Melt Gap
Pipe heads with adjustable melt gap allow automatic and fast pipe dimension change and are available for full-layer and coating dies.

Your advantages:

• Automatic pipe dimension change during production
• Significantly faster changeovers
• Increased safety for changing large-diameter dies
• Efficient extrusion lines with high throughputs
• High flexibility in pipe geometry and production planning
• Industry 4.0-compatible control for easy handling
• Excellent pipe quality with homogeneous surface and even wall thickness distribution

Our offer:

• Adjustable melt gap with electric motor available in sizes from 63 to 1,600 mm
• Standard SDR classes from 11 to 33 (additional SDR classes available on request)
• Adjustment almost independent of melt pressure (only die/mandrel area adjusted)
• Large diameter ranges via changeable die and mandrel extensions
• Compatible with OPTIMELT; retrofit possible for existing pipe heads

INTELLIGENT AUTOMATION
The helix II platform supports intelligent automation to simplify setup, improve process stability and reduce material waste by combining advanced centering technologies with automated die adjustment.

ICA – Intelligent Centering Adjustment (detailed)
ICA enables fast and reproducible inline centering of the die head. Mechanical or servo-controlled adjustment reduces changeover times, 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 (detailed)
IOA combines ICA with FDC (adjustable melt gap) to enable automated die adjustment for maximum production flexibility, improved process stability, reduced changeover times and optimized wall thickness distribution.

Your advantages:

• Combination of ICA and FDC
• Increased production flexibility
• Improved process stability
• Reduced changeover and start-up times
• Optimized product quality and reduced material consumption

Small diameter & functional pipe solutions
The helix II 32 VSI-MD is 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. The helix II 32-5 VSI enables accurate production of multilayer heating pipes with EVOH barrier layers while minimizing residence times.

Coat – pipe coating dies
Coat tooling melt distribution systems are configurable for specific product requirements. VSI two-step distributors can be used universally across melt viscosities enabling coating of pipes with HDPE, PP or recycled HDPE using the same coat tooling.

Your advantages:

• No time-consuming centering of 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 for outer and inner layers (e.g. PEX-b, adhesive, EVOH)
• 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 and large wall thicknesses

Special application: coat VSI – coating dies for multiducts/pipe bundles

Your advantages:

• Simple and cost-efficient implementation of individual bundle geometries
• Many different bundle geometries producible with one basic tooling
• Pipe bundles and coating do not stick together (thermal separation)

Our offer:

• Mono- or multi-layer coating of pipe bundles
• Special pipe guidance inside the tooling
• Option: frequency-controlled vacuum pump

Caractéristiques / spécifications techniques

• Model / series: helix II series (modular mono- and multi-layer PO pipe toolings)
• Patented 2-step distributor: spiral mandrel + lattice/screen basket distributor
• Pipe diameter range: microducts from ~5 mm up to very large diameters (projects > 2 m); EAC proven for 63–3,000 mm
• Wall thickness (EAC): up to 120 mm
• OPTIMELT enables wall thicknesses above 100 mm
• FDC adjustable melt gap available for sizes 63–1,600 mm
• Standard SDR classes: 11–33 (additional SDR classes on request)
• Microduct throughput example: up to 900 kg/h (helix II 32 VSI-MD)
• EAC cooling length reduction: 30%–50%
• Ventilator sound emission (EAC): max. 85 dBA at 1 m (sound-insulated)
• Features available: ICA, IOA, PMA, Heat Insulation, EAC, OPTIMELT, FDC
• Applicable materials: HDPE, PP, recycled HDPE, EVOH, PEX-b and other standard PO materials
• Modular design for easy retrofit, maintenance and cleaning; reduced color-change volume