In the production process of non-standard PVC drainage pipes, many manufacturers face the challenge of reducing production costs while ensuring the toughness and stability of the pipes.

One of our customers in the non-standard PVC drainage pipe industry at Rallychem encountered such an issue: In response to the fierce market demand, a customer increased the addition of calcium carbonate from 130 parts to 140 parts and made adjustments to the formula. However, after the adjustment, production became unstable, current fluctuations increased, and precipitation occurred, severely impacting product quality and production efficiency.

During this period, the customer tried various methods such as adding dispersants, adjusting the particle size of the calcium carbonate, optimizing lubricants, and altering the screw speed and hopper feed rate. In an attempt to resolve the issues, they not only replaced all the raw materials but also consulted three different solution providers. However, the quality of the pipes did not improve significantly; instead, more severe problems arose. The pipes exhibited poor impact resistance and insufficient toughness, and even broke when stepped on. This resulted in a significant waste of time and material costs, affecting the product's market competitiveness.

Rallychem Chemical's 5-Step Scientific SolutionFundamentally solving the customer's problem.

Ultimately, the customer chose Rallychem Chemical as their partner. Unlike other suppliers, Rallychem Chemical's advantage lies in providing a 5-step scientific, rigorous, and standardized solution service process. We not only provide products but also offer complete customized technical service solutions to our customers. From problem diagnosis to production improvement, we have helped our customers achieve a breakthrough in the performance of non-standard PVC pipes and significantly reduced production costs.

Understanding and confirming customer needs and issues.

We had an in-depth communication with the customer, gaining a detailed understanding of the technical issues they were facing, particularly the problems of internal and external lubrication precipitation, insufficient toughness, and brittleness in the production process of non-standard PVC drainage pipes. We further understood the customer's cost objectives and clarified the direction for improving product performance. This step is crucial to the success of the solution, ensuring that the solution we provide precisely meets the customer's actual needs.

Production Survey-Diagnosing the customer's existing formula and equipment.

Our technical team conducted a detailed survey of the customer's existing production formula, process flow, and equipment. Through in-depth communication with the customer and sample testing, we identified the following issues:

Lubrication system: The use of Fischer-Tropsch wax and stearic acid as the main lubricants tends to be easily sucked out and block the vacuum port, leading to insufficient lubrication in the later stages.

Filling system: After increasing the amount of calcium carbonate, the plasticization was inadequate, affecting the toughness and impact resistance of the pipes.

Low production capacity: It was lower than the conventional capacity of the equipment, and material scorching easily occurred when the speed was increased.

Therefore, optimizing the formula, improving product performance, and meeting the customer's cost requirements became our top priorities.

Solution:Comprehensive optimization from formula, process to equipment.

In response to the customer's specific needs and production bottlenecks, Rallychem Chemical developed a comprehensive solution based on polyester homopolymer toughening agent and polyester wax. As a new generation of hard-core toughening agents for PVC and CPVC, polyester homopolymer offers three significant advantages compared to traditional CPE, ACR, MBS, etc.:

1. Improves toughness without compromising rigidity.

2. Assists in thermal stability.

3. Enhances lubricity.

Polyester wax has a natural advantage in temperature resistance, making it particularly suitable for the production of PVC and CPVC. Compared to traditional internal and external lubricants, polyester wax provides lubrication protection throughout the extrusion process, with a smaller addition amount and higher efficiency. The production process of PVC pipes becomes smoother and more comfortable.

Based on the customer's actual on-site production situation, Rallychem Chemical's R&D center customized the formula for the solution and scheduled a time for on-site debugging.

Production Testing-Multi-stage verification of the feasibility of the solution.

During the implementation of the solution, Rallychem's  engineers maintained frequent communication with the customer and conducted small-scale, pilot-scale, and scale-up tests on-site. After real-time adjustments and multiple rounds of testing, significant improvements were made to the customer's production line thanks to the excellent synergistic effect of the polyester homopolymer and polyester wax. The processing performance and toughness of the non-standard PVC drainage pipes met the expected targets, and the production speed was also effectively increased, with costs kept within a controllable range.

Excellent Delivery-Efficient delivery of a comprehensive solution.

Eventually, we delivered a comprehensive technical solution to the customer and ensured its implementation effectiveness. With our technical support, the customer's PVC non-standard drainage pipe production line successfully achieved performance improvements, and production costs were effectively controlled, helping the customer gain a greater competitive advantage in the market.