A new factory with 14 extrusion lines, and an installed capacity of 2 2 00 tons a month, was commissioned by DPI Plastics in March. Located adjacent to the existing Roodekop facility in Johannesburg, the new factory will produce HDPE pipe up to 1 000 mm in diameter, and up to PN25 pressure class.
The factory consists of an entirely separate site that required new infrastructure such as cabling, power, water, stockyard, a laboratory and a raw-material store, DPI Plastics Technical and Product Manager Renier Snyman comments. “The new factory is operational at the moment,” he confirms.
Using only approved PE 100 raw material, the pipe will be manufactured in accordance with SANS 4427 (HDPE for water) and SANS 4437 (HDPE for gas). “Our production capability has tripled with the acquisition of these new machines,” Snyman reveals.
The Durothene-branded size range that will be produced ranges from 16 mm up to 1 000 mm, in pressure classes from 3 to 25. Smaller pipes up to a diameter of 110 mm are coiled in up to 100 m lengths. “Our laboratory has melt flow indexing (MFI) and oxidation induction time (OIT) testers to perform critical quality tests on our HDPE pipes,” Snyman explains. DPI Plastics also has a recycling facility where internal scrap is reworked into pellets that are tested and reused.
The latest addition enhances the manufacturing capabilities of DPI Plastics, which already boasts the largest PVC pipe production capability in Africa. Commissioned in 1980, the Roodekop factory has 15 extrusion lines, and an installed capacity of 2 700 t a month.
It produces PVC pipe in diameters from 50 mm up to 630 mm, and pressure classes from four to 25 bar. “This is the only factory in Africa that produces 630-mm-diameter PVC-m pipe,” Snyman confirms.
DPI Plastics also has an injection-moulding factory, with 18 injection moulders from 50 t to 575 t, and an installed capacity of 250 t a month. The factory produces PVC fittings from 40 mm to 160 mm, which are also trimmed, assembled, and packed on-site.
Mould and machine maintenance are taken care of by a fully functional tool room, with lathes, milling machines, and a spark eroder. Certain fitting configurations are fabricated separately by means of cutting and welding, while two 30 t presses fit steel Victaulic shoulders onto PVC high-impact and mining pipes.
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