Offline coiling
The principle of offline coiling is simple: separate the production of finished coils from the extrusion process, allowing the efficiency of the extrusion process and the coiling process to be maximised.
The benefits that can be gained from adopting this production method should not be underestimated. The fact that a "secondary operation" is involved compared to coiling directly at the end of the extrusion process is, in the majority of cases, far outweighed by the benefits that can be gained in terms of:
- increased extrusion output;
- reduced labour;
- reduced stock of finished coils; and
- reduced scrap.
For any factory that operates two or more extrusion lines on similar product sizes, offline coiling will offer a cost effective coiling solution.
The process
In an offline coiling system, the extruded product is wound onto a process drum at the extrusion line with the drums, typically sized to hold up to 24 hours of extrusion output.
The machine used to wind product onto the process drums is a relatively simple, low cost machine, but it operates automatically meaning that an operator is only required to perform drum changes every 24 hours. This practically eliminates the need for labour to oversee coiling at the end of the extrusion lines.
Process drums are then stored until finished coils are required, or can be moved immediately to the final coiling process as required.
Product is removed from the process drums using a fully automated and fully integrated rewind line consisting of a powered drum payoff machine, a tension control stand and an automatic coiler.
The rewind line operates at up to 150 m/min (650 ft/min ) producing packaged coils at rate of typically 100 coils per hour. The capacity of the rewind line allows one automatic coiler to handle the output from several extrusion lines. It is common for one high speed rewind line to coil the output from four to five lines extrusion lines.
Offline systems offer a quick return on the investment
The investment cost for such an offline system is much lower than that of purchasing an automatic coiler for each extrusion line. In addition, the lower labour cost to operate the offline system and the extrusion rate increases that may be possible with offline coiling will result in a significantly better return on investment.
Most offline systems give a return on investment of 30% to 50% and it has been known for 100% return on investment to be attained. Pipe Coil Technology Limited provide all equipment necessary to implement an offline coiling system, including process drums and equipment for performing drum movements within the factory.
Contact us
If you would like to discuss your specific requirements, please contact us.