Polestar small tube production line
2 month ago
Product details
Small Diameter Medical Grade PVC Hose/Tube Extrusion Line
1. SJ45/28 Extruder:
Features a screw diameter of 45mm and a length-to-diameter (L/D) ratio of 28:1. This provides excellent melting, homogenization, and stable melt pressure control, crucial for consistent wall thickness and diameter in small, precise tubing.
Precision Gear Pump: Often integrated downstream of the extruder to provide absolutely constant, pulseless melt flow to the die, eliminating pressure variations and significantly enhancing dimensional accuracy (±0.05mm or better achievable).
Micro-Precision Tubing Die: Specifically designed for small diameters (typically sub-1mm to a few mm), featuring tight tolerances and optimized flow channels for uniform distribution of the PVC melt.
2. Advanced Sizing & Calibration:
Vacuum Sizing Tanks: Multiple precisely controlled vacuum tanks with custom sizing sleeves/plates ensure the molten tubing is gently and accurately formed to the exact outer diameter (OD) specification immediately after exiting the die.
Precision Internal Air Pressure Control: Maintains precise control of the internal diameter (ID) and concentricity. Sophisticated systems regulate air pressure or mandrel position with high accuracy.
Closed-Loop Diameter Control System: Utilizes high-resolution laser micrometers continuously measuring the OD and providing real-time feedback to automatically adjust line speed, vacuum, internal pressure, or haul-off tension to maintain target dimensions.
3. Superior Cooling:
Multi-Stage Cooling Tanks: Long, cascaded cooling tanks ensure the PVC tubing is cooled gradually and uniformly from the melt state to prevent stress, warpage, or ovality, which is critical for high precision and performance.
Precise Temperature Control: Individual control of water temperature in each cooling section optimizes the cooling profile for the specific PVC compound and tube dimensions.
4. Gentle & Precise Haul-Off:
Haul-Offs with Precision Belts: Equipped with high efficiency, PU surface wear-resistant wedge belt, composed of precision linear guides, synchronous belt drive, smooth transmission. Be used for ultra-small diameters where minimal contact is needed, offering extremely precise speed control.
5. High-Accuracy Cutting:
Servo-Driven Flying Cutters: Provide clean, burr-free cuts to exact lengths (±0.5mm or better tolerance common) without stopping the line or damaging the tubing, even at high production speeds.
6. Medical-Grade Compliance & Cleanliness:
Material Handling: Systems designed to handle medical-grade PVC compounds with minimal contamination risk.
Cleanliness Focus: Constructed with materials and designs suitable for medical manufacturing environments. Often includes cleanroom compatibility features.
Traceability: Capable of integration with production data monitoring systems (SCADA/MES) for lot traceability and process parameter logging, essential for medical device manufacturing.
7. Process Control & Monitoring:
Centralized HMI/PLC Control: Modern touchscreen interface for comprehensive control, monitoring, and recipe management of all line parameters (temperatures, speeds, pressures, vacuums, dimensions).
Integrated Sensors: Continuous monitoring of melt pressure, melt temperature (before die), cooling water temperature, line speed, vacuum levels, etc.
Real-time Dimension Monitoring: As mentioned, laser micrometers and potentially ultrasonic wall thickness gauges provide continuous SPC data.
8. Designed for Small Diameters:
Low Output Rate: The SJ45/28 extruder is appropriately sized for the relatively low volumetric output required for small-diameter tubing production.
Handling Systems: Capstans, guides, and accumulators designed to manage fragile, small-diameter tubing without kinking or damage.
9. In summary:
This production line leverages the precise melt delivery of the SJ45/28 extruder, combined with advanced sizing (vacuum + internal pressure), laser-controlled closed-loop dimensioning, ultra-stable haul-off, clean medical-grade design, and sophisticated process control to consistently produce small-diameter PVC tubing with the tight tolerances, high concentricity, surface quality, and biocompatibility required for demanding medical applications.
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Zhangjiagang Polestar Machinery Co.,Ltd
Audited supplier
2 year
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