A leading integrated steel and ductile iron (DI) pipe manufacturer in Eastern India decided to diversify into the production of OPVC (Oriented Polyvinyl Chloride) pipes as a modern alternative to traditional DI pipelines.
The demand for lightweight, corrosion-resistant, and high-pressure piping systems in municipal water distribution projects has increased. The company invested in an advanced OPVC extrusion line at its Durgapur facility.
Since OPVC manufacturing requires highly controlled cooling conditions throughout the extrusion process, the company needed a reliable industrial cooling solution capable of maintaining precise temperatures during continuous production.
After evaluating the process requirements, Tempcon engineered and supplied an 80 TR Water-Cooled Screw Chiller with Stepless Capacity Control, specifically designed to support the cooling demands of the OPVC extrusion process
About The Client
The client is one of India’s established integrated steel producers with decades of experience in manufacturing ductile iron pipes for water transmission and infrastructure projects.
Recognising the growing acceptance of OPVC pipes as a cost-effective and high-performance alternative to DI pipes, the company expanded into OPVC manufacturing to serve government, municipal, and industrial water distribution projects.
The new production line required dependable process cooling to ensure consistent product quality and maximise production efficiency.
Existing Cooling Challenges in the Panel Room
OPVC production differs significantly from conventional PVC pipe manufacturing. The process involves precise orientation of the pipe material under controlled temperature conditions to achieve superior
Extruder Cooling Requirements
The extrusion process generates significant heat due to the following:
- High screw speeds
- Continuous material processing
- Frictional heat generation
- Heater band operation
Any variation in cooling water temperature can affect pipe dimensions and mechanical properties.
Calibration and Downstream Cooling
The downstream section requires stable cooling water circulation to maintain:
- Proper pipe orientation
- Consistent wall thickness
- Dimensional accuracy
- Surface finish
Inconsistent cooling can lead to product rejection and reduced production efficiency.
Continuous Operation Requirement
The plant was designed for round-the-clock production. Therefore, the cooling system needed to deliver:
- Reliable performance
- Energy efficiency
- Stable chilled water temperatures
- Ability to handle varying process loads
Tempcon’s Engineering Approach
Before recommending a solution, Tempcon’s engineering team conducted detailed discussions with the client’s technical team to understand:
- Production capacity
- Extrusion line configuration
- Water circulation requirements
- Seasonal operating conditions
- Future expansion plans
Based on process load calculations and cooling demand analysis, Tempcon proposed an 80 TR Water-Cooled Screw Chiller equipped with:
- High-efficiency screw compressor
- Shell-and-tube evaporator
- Shell-and-tube condenser
- Industrial-grade control system
- Stepless Capacity Control mechanism
The solution was specifically designed for continuous industrial operation.
When production loads decrease, the compressor reduces capacity rather than operating at full load, resulting in lower power consumption.
Reduced Compressor Stress
Smooth capacity modulation minimises frequent loading and unloading cycles, improving compressor life and reliability.
Better Process Control
The extrusion line receives only the cooling capacity required at a given moment, ensuring stable process conditions and consistent product quality.
Stable Cooling for OPVC Extrusion
The chiller maintains a consistent chilled water supply to support the entire extrusion process.
Heavy-Duty Industrial Construction
Designed for continuous industrial duty and demanding operating environments.
High Operational Reliability
Industrial-grade components ensure dependable performance during long production cycles.
Energy-Efficient Operation
Stepless capacity control helps optimise energy consumption while maintaining process temperatures.
Low Maintenance Requirements
The water-cooled screw chiller design offers long service life and reduced maintenance downtime.
Following commissioning, the client achieved significant improvements in process stability and production efficiency.
Consistent Product Quality
Stable cooling temperatures improved the dimensional accuracy and mechanical properties of OPVC pipes.
Smooth Production Operation
The extrusion line operated without temperature-related interruptions, reducing production risks.
Improved Energy Efficiency
The stepless capacity control system optimised compressor operation according to actual process demand.
Enhanced Equipment Reliability
Stable cooling reduced thermal stress on production equipment and improved overall operational performance.
Support for Future Growth
The cooling system provided sufficient capacity and flexibility to support increasing production requirements.
Conclusion
The successful installation of Tempcon’s 80 TR Water-Cooled Screw Chiller with Stepless Capacity Control helped the client establish a reliable and efficient OPVC pipe manufacturing operation.
As a long-established DI pipe manufacturer entering the OPVC segment, the client required a cooling solution capable of delivering precise temperature control, energy efficiency, and long-term reliability. Tempcon’s engineered solution met these objectives and contributed to smooth plant operation and consistent product quality.
This project further demonstrates Tempcon’s expertise in providing specialised industrial cooling solutions for advanced extrusion applications and reinforces its position as a trusted partner for the OPVC pipe manufacturing industry.
100%
Temperature Consistency
0%
Spoilage Due To Temperature Misalignment
30%
Reduction in Energy Coss
