Elevating Quality Standards for a Recycled Plastic Pipe Manufacturer

Challenge:
A pioneer in sustainable infrastructure solutions faced critical defects in its recycled HDPE/PP pipes: persistent internal microbubbles and subpar surface finish (Ra > 12.5 μm). These flaws caused 18% rejection rates, breached GB/T 19472.2-2017 national standards, and jeopardized municipal construction contracts worth $3.5M annually.

Engineering Breakthrough:
Avian developed a vented single-screw extruder featuring:

1. Advanced Degassing Design:

   • Triple decompression zones reduced volatiles by 92% through optimized vacuum vent positioning.

   • Grooved barrel sections enhanced surface renewal for efficient gas expulsion.

2. Dynamic Compression Profile:

   • Progressive 3:1 to 2.5:1 compression ratio eliminated melt pressure fluctuations.

   • Conical transition sections stabilized flow to prevent bubble re-entrapment.

Validated Results:

• ↓ 95% Bubble Incidence: X-ray tomography confirmed voids < 0.05% volume (vs. industry avg. 1.2%).

• Surface Perfection: Roughness reduced to Ra 3.2 μm (ISO 4287), enabling glossy Class-A finishes.

• Quality Certification: Achieved ISO 4427:2019 & WRAS approval for potable water systems.

• Operational Gains:

  • ↓ 30% energy consumption via reduced backpressure

  • ↑ 22% line speed through stabilized melt flow

• Market Impact: Secured $6.8M in new contracts, capturing 15% additional market share in 8 months.

Technical Precision:
The screw’s melt-cooling channels maintained precise 185±5°C temperature control, preventing polymer degradation. Barrier flights segregated unmelted particles, reducing gel defects by 80%. Post-installation, pipe pressure resistance surged to PN16 rating (ISO 4065), exceeding infrastructure requirements by 60%.

Sustainability Legacy:
This innovation enabled 100% recycled content in pressure pipes—diverting 8,500 tonnes/year from landfills. Municipalities now deploy these pipes in earthquake-resistant water networks, while the manufacturer’s ESG score improved 35%, attracting green bond investments.