How to Permanently Solve Impact Issues and Weight Variation in HDPE Pipes

Producing high-density polyethylene (HDPE) pipes with large diameters presents several engineering challenges. Among the most common are weight inconsistencies, uneven wall thickness, and reduced impact resistance. These factors can compromise both product performance and production efficiency.

Bausano designs tailored extrusion solutions to permanently eliminate these issues, ensuring consistent quality and optimized productivity across the entire process.

High L/D Ratio: For Perfect Material Homogenization

A high length-to-diameter (L/D) ratio in the extruder is essential to achieve complete homogenization of the polymer. This promotes thorough material mixing, minimizes internal inconsistencies, and significantly enhances the mechanical strength of the pipe.

Cylindrical Spiral Die Head: Uniform Melt Flow and Thickness

To ensure a constant and uniform melt flow, Bausano employs cylindrical spiral die heads. This technology eliminates thickness and weight variations along the pipe, contributing to improved process stability and product consistency.

Internal Pipe Cooling (IPC): Shorter Cycles, Higher Resistance

Bausano’s patented Internal Pipe Cooling (IPC) system actively cools the pipe from the inside. This innovation shortens cycle times, maintains dimensional stability, and increases the pipe’s resistance to impact — a crucial factor in large-diameter applications.

Optimized Granule Drying: A Key to Surface Quality

Proper drying of the polymer granules prevents surface defects, poor flowability, and internal bubbles. Bausano places special emphasis on this step to ensure optimal processing and aesthetic results.

Pipes with Wall Thickness Above 35 mm: Best Practices

For pipes exceeding 35 mm in wall thickness, Bausano recommends the following best practices:

• Use of low-sag materials
• Thermal centring during processing
• Accurate die gap and tooling calibration

These adjustments, although subtle, have a significant impact on structural integrity and dimensional precision.

Applied Expertise for Reliable Performance

Thanks to its in-depth industry knowledge and a customer-specific approach, Bausano offers solutions that address the most complex challenges in HDPE pipe production. Every component of its extrusion lines is engineered to ensure maximum operational efficiency, uniform output, and long-term reliability.

To discover how Bausano can support your production goals with tailored solutions, get in touch with our team of experts. Contact us.