PVC pipe extrusion Bausano boosts PVC extrusion output with longer barrel configuration

Bausano has introduced an L/D 34 configuration for its MD series of counter-rotating twin-screw extruders. Comparative trials in PVC pipe production showed up to 14 percent higher throughput and lower specific energy consumption, demonstrating the potential of longer barrels without increasing extruder size.

Maximising output by extending barrel length rather than increasing extruder size: this is the principle behind Bausano’s new L/D 34 configuration, compatible with all counter-rotating twin-screw extruders in the MD series. The innovative solution expands the capabilities of PVC pipe extrusion technology, combining higher throughput, energy efficiency and control over melt quality.

“The true value of innovation lies in achieving more from existing technologies by rethinking their potential through research and scientific validation,” comments Massimiliano Fenili, Technical Manager at Bausano. He continues: “With the L/D 34 configuration, we explored a design approach that offers an alternative to increasing extruder size, providing processors with new opportunities to optimise their production processes and make more efficient use of capital investment.”

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Extended barrel and multidrive: A synergy that enhances extrusion

The extended barrel distributes PVC gelation and filler dispersion over a longer screw section, increasing material residence time and enabling higher throughputs without resorting to aggressive mixing geometries that could compromise the thermal stability of PVC.

The configuration also integrates Multidrive, Bausano’s patented drive system, available in 2×2 and 4×2 versions. Depending on extruder size, torque is distributed across two or four synchronised asynchronous motors. This works alongside temperature-controlled screws, degassing, induction barrel heating, a lubrication unit and gearbox temperature control. IIoT monitoring completes the solution, enabling more effective management of production parameters.

Performance is measured by data

At Bausano, the reliability of a solution is assessed through verifiable data and analyses conducted under actual operating conditions. The R&D department applies a rigorous methodology to turn performance into tangible evidence, supporting customers’ Capex decisions and production efficiency. Tests assessed the performance of the MD75 with an L/D 34 configuration through two experimental comparisons. The first, against the MD92/30, evaluated its potential relative to a larger extruder. The second, against the MD75/30, measured the effect of a longer barrel on output at the same machine size. The trials covered two distinct applications: PVC pipes for pressurised water supply and non-pressure PVC drainage pipes, for which higher mineral filler contents are permitted. For each application, throughput, energy consumption and process parameters were recorded and compared to provide an objective assessment of the results.

MD75/34: Efficiency in figures

In trials involving PVC pipes for pressurised water supply, the MD75/34 achieved a throughput of 450 kg/h, matching that of the larger MD92/30, with 40 percent lower installed power (44 kW versus 74 kW). At the same throughput, specific energy consumption per kilogram of product was 17 percent lower, at 0.107 kWh/kg compared with 0.129 kWh/kg. Moreover, across the 100–450 kg/h throughput range, energy savings varied between 19 percent and 35 percent, averaging 27 percent.

In the production of non-pressure PVC drainage pipes, the comparison with the MD75/30, both equipped with 2 × 22 kW motors, also revealed several advantages. The MD75/34 configuration increased throughput by 14 percent, from 350 to 400 kg/h, while significantly reducing melt temperature and maintaining an adequate degree of gelation. These results demonstrate higher productivity combined with a lower melt temperature at the die head, allowing improved process control.

“These results must be interpreted in the context of the individual test conditions, but clearly demonstrate the potential of extending the barrel,” adds Massimiliano Fenili, Technical Manager at Bausano. He concludes: “The detailed comparative analyses not only confirmed the added value of this mechanical configuration but also identified further scope for improvement, particularly in dry-blend feeding for formulations with high CaCO₃ content.”

From test data to production-line data

The MD75/34 is also complemented by Sphere, Bausano’s digital ecosystem, natively integrated into the line. It combines IIoT technologies and artificial intelligence to turn process data into actionable information. The system consists of two complementary modules: Pharos, a cloud-based IIoT platform that continuously collects and processes machine and process data, and Ranger, an AI platform that interprets those data in relation to actual operating conditions. Alongside the value derived from data, Bausano also prioritises their protection, with an approach centred on confidentiality and regulatory compliance. The data remain the customer’s property, supported by the system’s stated compliance with the NIS2 Directive and Regulation (EU) 2023/1230.

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