POLYMERIC PRODUCTS:

Many different polymeric products are produced from a variety of techniques such as injection
molding, compression molding, blow molding, foaming, thermoforming, extrusion etc. Polymer
products manufactured from these processes are:

• Tennis shoes
• Clothes
• Computer
• CDs/DVDs
• Pens
• Glasses
• Paints
• Adhesives
• Chairs
• Pipes
• Sports industry
MANUFACTURING OF PVC PIPES:
PVC pipes are made out of a material known as polyvinyl chloride, a durable, strong plastic like
substance. Pipes are constructed from this material and used in various applications from plumbing
to construction. The pipe is designed to be universal. All pipes are designed around specific
requirements to ensure that multiple pipe sections will fit together. The ends of the pipe can either
be smooth or grooved (similar to a screw). Additionally, there are several different pipe sizes
ranging from very small (one-fourth inch) to very large (10 feet).

Figure 1: PVC pipes used in plumbing

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RAW MATERIALS:
The two raw materials used in the manufacture of PVC are sea water and oil. Salt derived from
sea water is used to make chlorine gas and petroleum oil is the original source for ethylene gas.
Chlorine and ethylene are the two main ingredients needed to make PVC.
CHLORINE:
Chlorine is produced from a saline solution by the process of electrolysis. A solution of sodium
chlorine, or common table salt, is placed in a container with electrodes. When electric current is
applied, the positive electrode attracts chloride ions in the solution where they combine to form
chlorine gas.
ETHYLENE:
Ethylene is a colorless and odorless gas with the chemical formula C2H4. It is highly flammable
and can cause explosions if mishandled. It is produced commercially from the refining of
petroleum.
MAKING PVC:
The chlorine and ethylene gases are combined to produce ethylene dichloride which is converted
at high temperatures to vinyl chloride (CH2=CHCl). The vinyl chloride molecules are then
polymerized to form the PVC resin. Other compounds are added to improve its appearance and
physical and chemical properties. The finished product is formed into pipe or other products where
it hardens as it cools.
ADDITIVES:
A number of compounds can be added to raw PVC. The most common additives are pigments to
add color, UV inhibitors to protect the material from being degraded by prolonged exposure to
sunlight, and plasticizers to adjust the degree of flexibility of the specific product. Most plasticizers
come from a chemical group called phthalates.
TOXICITY OF MATERIALS:
Chlorine in the gaseous form is dangerous because it is a severe irritant to the skin, eyes, and
respiratory system. Ethylene chloride compounds that are made in the manufacturing process and
not converted into polymers are known to be carcinogenic. There are remnants of these compounds
that are not combined in the finished PVC which makes water pipe and other products potentially
hazardous as well. The phthalates that are used as to increase plasticity are also very toxic.

Figure 2: Flow sheet of PVC production

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GRADES OF PVC RESIN:
There are 4 types of PVC Resin grouped by polymerization method:
1. Suspension Grade PVC
2. Emulsion Grade PVC
3. Bulk Polymerized PVC
4. Copolymer PVC
1. Suspension Grade PVC:
The most widely prevalent type, Suspension grade PVC is made by polymerizing droplets of vinyl
chloride monomer suspended in water. When polymerization is complete, the slurry is centrifuged
and the PVC cake is gently dried by special heating systems so as not to subject the unstabilised
resin to heat degradation. Particle size of the resin ranges from 50-250 microns and have porous
popcorn like structures which readily absorbs plasticizers. The structure of the PVC particles can
be modified by selecting suitable suspending agents and polymerization catalyst. Less porous types
are extensively used for the high volume rigid or unplasticised PVC applications like PVC pipes,
windows, sidings, ductings. Suspension grades of a coarser particle size and very porous structures
absorb large quantities of plasticizer forming a dry blend at temperatures as low as 80oC.The more
porous types are used in plasticized applications like cables, footwear, soft calendered sheeting
and films etc.

Figure 3: Suspension polymerization of PVC resin

2. Emulsion Grade PVC:

Emulsion polymerized PVC is what paste grade resin is and this is almost exclusively used for
plastisols. Paste grade resin is a very fine particle size PVC produced by spray drying an emulsion

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of PVC in water very much like how milk powder is produced. Paste grade resin needs much more
energy to produce and is considerably costlier than suspension resin. The paste grade resin carries
the emulsifying chemicals and catalysts with it. It is therefore less pure than suspension
polymerized or bulk polymerized PVC. The electrical properties of paste grade resin plastisols are
therefore much poorer than Suspension Resin Compounds. Clarity is poorer than suspension or
bulk PVC. Paste grade resin is compact in structure, and does not absorb much plasticizer at room
temperatures. Temperatures in excess of 160-180oC are needed to drive the plasticizer into the
resin during curing. Paste grade resin is extensively used for cushion vinyl floorings of wide
widths.

Figure 4: Emulsion grade PVC production

3. Bulk Polymerized PVC:

Bulk Polymerization gives the purest form of PVC resin as no emulsifying or suspending agents
are used. They are mainly used in transparent applications. They are mainly made available in the
lower K value groups, as Unplasticised PVC foils for blister packaging and other
calendered/extruded transparent films are best processed from lower K value grades. Refinements
in suspension resin technology has edged out bulk PVC in the recent past.

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 Figure 5: Bulk polymerization of vinyl chloride

4. Copolymer PVC:
Vinyl chloride is copolymerized with co-monomers like vinyl acetate give a range of resins with
unique properties. PVAc or copolymer of vinyl chloride and vinyl acetate is the most important.
The good solubility in solvents of PVAc makes it the prime choice for vinyl printing inks and
solvent cements. There is a very special application of PVAc in floor tiling and it is the resin of
choice for vinyl asbestos tiles. The resin is actually a binder rather than the main ingredient. With
copolymer resin it is possible to manufacture floor tiles with fillers like asbestos and calcium
Carbonate accounting for as much as 84% with the copolymer and other compounding additives
as low as 16%. Such high levels are not possible with suspension resin as its melt viscosity is
much higher and cannot coat and encapsulate such high levels of inert filler. Special calendering
trains are required for vinyl asbestos tiles.
K Value:
PVC Resins are classified by their K-Value, an indicator of the molecular weight and degree of
polymerization.
• K70-75 are high K value resins which gives best mechanical properties but are more
difficult to process. They need more plasticizer for same softness. High performance cable
insulations in suspension resin and tough coatings for conveyor belts, industrial flooring
and similar high end applications in paste grade are some popular application. It is the
costliest.
• K65-68 is medium K value resin which are the most popular. They have a good balance of
mechanical properties and processibility. UPVC (Unplasticised or Rigid PVC) is made

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 from the less porous grades while plasticized applications are best made from the more
porous grades. There is a lot of grade choice as they cater to the majority of PVC
applications. Because of its sheer volume this family of PVC resins are priced the lowest.
• K58-60 are low K-value ranges. Mechanical properties are lowest, but processing is
easiest. Many difficult to process applications like injection moulding, blow moulding and
clear calendered packaging film are made from the lower K value ranges. Prices are higher
than medium K value resins.
• K50-55 are special resins which are tailor made for some demanding applications.
Interesting ones are battery separator resins and blending resins used along with paste grade
resin to reduce costs. Processing is easiest. As PVC is 56% chlorine, it is one of the few
polymers which are self extinguishing, as chlorine is a strong flame inhibitor.

TECHNIQUES OF MANUFACTURING OF PVC PIPES:

PVC pipe extrusion line is one of the most common plastic pipe machine. The production process
of PVC pipe extrusion machine are as follows:
1. Mixing the raw material:
Put the PVC stabilizers, plasticizers, antioxidants and other excipients in proportion into the high
speed mixer according to the process order, when the mixer working, the material are warmed to
the setting process temperature by the friction function between materials and machinery, and then
by cold mixing machine the material was dropped to 40-50 degrees. Then the mixed material can
be put into the hopper of the extruder.
2. The extruder working:
The machine is equipped with a dosing device which can ensure the extrusion amount and feeding
amount and ensure that the products can be stable extrusion. Due to the characteristics of the
conical screw, the feed section has a larger diameter, the heat transfer area and the shear rate of
material are relatively large, which if beneficial for material plasticization.
3. Extrusion die function:
The compaction, melting and kneading PVC are pushed to the extrusion die head by the
homogenized subsequent material, the extrusion die head is the crucial parts for pipe molding.
4. Vacuum calibration tank:
It is used for pipes cooling and stereotypes. The vacuum sizing tank is equipped with vacuum
stereotypes and cooling system and water circulation system, adopting stainless steel cabinet,
circulating water spray cooling.
5. Haul-off machine (tractor):
It is used for pull the cooled and hardened pipes out from the die head continuously and
automatically, and frequency controls the speed.
6. Cut pipes by cutting machine:
It automatically cuts according to the requirements length of the control by the travel switch, and
turning frame in a set delay time.

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 Figure 6: PVC pipe extrusion line

MACHINE & ITS SPECIFICATIONS:

PVC Pipe Extrusion Line, PVC Pipe Production Line, PVC Pipe Making Machine
 Applicable Products: PVC Pipe
 Applicable Materials: PVC
 Alias: PVC Pipe Production Line, PVC Pipe Making Machine, PVC Pipe Machine, PVC Pipe
Line, PVC Pipe Extruder
The complete PVC Pipe Extrusion Machine consists of:
1. Feeder:
Used for feeding the material to the extruder.
2. The core part of the pipe extrusion line, the quality of the pipe mostly depends on the quality of
the mold.
3. Vacuum Calibrating and Cooling Tank:
Good vacuum calibrating and cooling tank makes the pipe looks nice, more than one set of
vacuum calibrating and cooling tank will be needed for making big diameter pipe.
4. Water Cooling Tank:
Pipe comes from mold is hot, it is still very hot even after cooling by the vacuum calibrating and
cooling tank, so the water cooling tank is needed for cooling the pipe. Generally speaking, the
bigger diameter need the longer water tank.
5. Haul-off unit:
Haul-off unit is a device which pull the pipe goes forward. There are several different models
which are sorted by the quantity of the claw(caterpillar).
6. Cutter:
The cutter of the PVC pipe extrusion line is automatic and digital controlled, which is world
leading. Its operation is easy while its performance is excellent and stable
7. Socketing Machine(Belling Machine):
This machine is optional, it can make the socket online if to equipped with automatic belling
machine.
8. Stacker:
For collecting the pipes.

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This PVC Rigid Pipe Making Machine is mainly used in the manufacture of the PVC pipes with
various diameters(16-630mm) and wall thickness in the aspects such as the agricultural and
constructional plumbing, cable laying etc.

TECHNICAL INFORMATION OF PVC EXTRUSION LINE:

PRODUCT QUALITIES:
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 pipes are used in a wide variety of piping applications, from transportation of drinking water
over drainage solutions to advanced fire-sprinkler systems. This popularity owes to a unique

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combination of properties: safety, durability/cost-efficiency, environmental performance and
recyclability.
REFERENCES:
1. http://www.plastemart.com/upload/literature/essential-compounding-chemicals-used-
with-PVC-resin-primary-secondary-plasticiser-heat-light-stabilisers.asp
2. https://www.creativemechanisms.com/blog/everything-you-need-to-know-about-pvc-
plastic
3. https://pvc4pipes.com/pvc-pipes/why-pvc-pipes/