Extrusion International 6-2025

46 Extrusion International 6/2025 MEASUREMENT AND CONTROL TECHNOLOGY – CASE STUDY Improved Quality in PE-Xa Pipe Production 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-ef cient 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 rang- ing from Ø 63 to Ø 140 mm). These applications de- mand high precision in pipe dimensions and structural integrity to meet both customer speci cations 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 speci c 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 con gurations, 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 so- lutions, iES selected a range of measurement and con- trol 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 measure- ment of pipe dimensions. Additionally, iES integrated the KW optical measuring device for surface detection of faults, lumps and neckdowns. These systems are de- ployed 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 thick- ness and ovality; and at the nal stage after the applica - tion 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 pro- cess. 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 sys-