Intelligent Extrusion Systems (iES) Elevates PE-Xa Pipe Quality Production with Zumbach Electronic Integration

One of the leading manufacturers of extrusion lines for PE-Xa (peroxide cross-linked polyethylene) pipes, Intelligent Extrusion Systems (iES), has successfully integrated advanced measurement and control systems from Zumbach Electronic into their production lines.

This strategic move has empowered iES to deliver superior product quality, ensure compliance with international regulatory standards, and maintain cost-efficient manufacturing tolerances.

PE-Xa pipes are widely used in hot and cold water plumbing, heating systems (in sizes ranging from Ø 12 to Ø 63 mm), and industrial applications, (in sizes ranging from Ø 63 to Ø 140 mm). These applications demand high precision in pipe dimensions and structural integrity to meet both customer specifications as well as stringent regulatory standards across a multitude of different countries.

To achieve this, iES required a robust solution that could monitor and control pipe dimensions with specific attention to the outer diameter, inner diameter, wall thickness and ovality. Additionally, the solution had to be able to detect surface defects, ensure consistent quality across multiple production configurations, and maintain tight manufacturing tolerances to optimize material usage and cost.

After a prolonged consultation marked by rigorous evaluation and analysis of Zumbach’s products and solutions, iES selected a range of measurement and control systems for integration into their extrusion lines that included the UMAC® Ultrasonic Measuring System, ODAC® TRIO Laser Measuring Heads, and the USYS IPC processor and controller, used for real-time measurement of pipe dimensions. Additionally, iES integrated the KW optical measuring device for surface detection of faults, lumps and neckdowns. These systems are deployed at critical stages of the extrusion process: at the initial stage for measurement and control of the inner PE-Xa layer’s outer diameter, inner diameter, wall thickness and ovality; and at the final stage after the application of additional layers, re-checking the diameter and ovality and performing defect detection in accordance with the customer’s requirement and/or regulatory standard.

Technical Director at iES, Juan Carlos Martinez stated “By integrating Zumbach’s precision measurement and control technologies, iES has achieved total production control. The real-time feedback provided by Zumbach’s solutions allow for immediate adjustments, ensuring consistent product quality through our extrusion process. This control has also enabled our products to meet the regulatory compliance standards for each target market, reducing the necessity to rework, which in turn reduces material waste, and lowers production costs.”

The enhanced product quality and reliability provided by integrating Zumbach’s measurement and control systems has strengthened iES’s reputation and improved customer satisfaction. The partnership between iES and Zumbach Electronic exemplifies how smart integration of measurement technology can transform manufacturing outcomes. With Zumbach systems embedded in their extrusion lines, iES continues to lead the way in producing high-quality PE-Xa pipes.