Coating extrusion die helix II

for plastic pipesfor extrusionmulti-layer

Product summary
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.

Overview
Customized mono- and multi-layer tooling for a wide range of customer requirements. The unique VSI dies feature a patented 2-step distribution concept consisting of a spiral mandrel for preliminary distribution and a lattice basket (screen) distributor for final melt distribution, enabling high throughput rates with compact die dimensions. The modular design allows individual adaptation to customer-specific requirements. The portfolio also includes modular coating dies adaptable 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 (key benefits)

• Equipped with a patented 2-step distributor concept: spiral mandrel for preliminary distribution and screen basket distributor for fine distribution
• Reduced gloss streak formation through gentle melt distribution
• Compact design for easier handling and assembly
• Smaller volume shortens color change times
• Easy cleaning and maintenance thanks to separate distribution systems for each 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 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 spiral mandrel, radial or side-fed distributors as desired. The optimal distribution concept is selected depending on the materials to be processed.

Your advantages

• Ideal distribution concept for the specific material
• Minimal effort for servicing and cleaning due to strategically positioned parting lines without dismantling other components
• Long tooling service life
• Application-specific coatings available for wear protection, optimized flow behaviour and surface sealing

Our offer

• Top-quality distribution of functional layers across the circumference and therefore 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 and EVOH)

Melt distribution concepts

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

EAC – Efficient Air Cooling (internal pipe cooling)
With the EAC internal pipe cooling system, additional internal pipe cooling with an air current against the extrusion direction enables higher throughputs and reduced cooling lengths.

Your advantages

• Reduce required cooling length by 30–50% or alternatively increase throughput
• Improved pipe geometry and roundness
• Energy savings by use of exhaust air for pre-heating granulates
• Simple retrofitting of existing VSI toolings

Offer details

• Proven EAC for pipe diameters from 63 to 3,000 mm and wall thicknesses up to 120 mm
• Very powerful, frequency-inverter-controllable ventilators
• Ventilator sound-insulated (max. 85 dBA at 1 m)
• Permanent exhaust air system with thermal insulation and integrated air filter

OPTIMELT – Active Melt Cooling for Thick-Wall Pipe Extrusion
OPTIMELT actively reduces melt temperature directly before the die head to minimize sagging, improve 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 (FDC) enable automatic dimension change and fast changeovers, supporting full-layer and coating dies and retrofit possibilities.

Your advantages

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

Offer details

• 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 on request)
• Adjustment almost independent of melt pressure
• Large diameter ranges possible with changeable die and mandrel extensions
• Can be combined with OPTIMELT
• Retrofit possible for existing pipe heads

Intelligent Automation
The helix II platform can be equipped with intelligent automation solutions combining advanced centering technologies and automated die adjustment to simplify setup, improve stability and reduce material waste (ICA, IOA, PMA integration).

Small diameter & functional pipe solutions

• helix II 32 VSI-MD: developed for microduct production, throughput rates up to 900 kg/h; suitable for mono- and multilayer pipes, silicone layers, ribbed inner surfaces and inline wire insertion
• helix II 32-5 VSI: 5-layer PERT pipe head for highly accurate 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 waste and downtime

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

• Mono- or multi-layer coating of pipe bundles
• 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)
• 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 product requirements; VSI two-step distributors are usable across a wide range of melt viscosities, enabling coating of pipes with HDPE, PP or recycled HDPE using the same coat tooling.

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

Caractéristiques / spécifications techniques

• Denomination: helix II series (VSI distribution technology with patented 2-step distributor)
• Applicable pipe diameters: from microducts (e.g. 5 mm) up to very large diameters (project experience > 2 m); EAC proven for 63–3,000 mm
• Wall thickness capability: EAC up to 120 mm; OPTIMELT enables wall thicknesses above 100 mm
• Adjustable melt gap (FDC) available for sizes 63–1,600 mm; SDR classes standard 11–33 (others on request)
• helix II 32 VSI-MD throughput up to 900 kg/h for microduct production
• Modular coating dies support HDPE, PP and recycled HDPE outer layers and multiple inner layers (adhesive/EVOH combinations)
• Available features: ICA (Intelligent Centering Adjustment), IOA (Intelligent Operation Adjustment = ICA + FDC), PMA (Pipehead Measuring Aid), insulation jackets, EAC, OPTIMELT
• Options: spiral mandrel, radial, side-fed or spider-type mandrel distributors; frequency-controlled vacuum pump for coating applications