Safe processes and utmost reliability: the medical industry sets strict criteria for the production of medical devices. Medical tubes, in particular, require the highest quality in terms of dimensional accuracy, surface type and complete absence of contamination. The new high-speed extrusion line for PVC medical tubes by Bausano – a leading international player in the design and production of customised extrusion lines for plastics processing – meets the most stringent requirements, such as ISO 14644-1 Class 8 Cleanroom, thanks to the strict design criteria adopted, which also ensure high performance in terms of quantity and energy.
In detail, the high-speed line is capable, even in the most compact configuration, of producing up to 120m of tube per minute. Bausano, indeed, customises each plant based on the Customer’s needs, also with regard to the occupied ground volume, through innovative solutions aimed at reducing the size with the same production capacity.
This unprecedented solution is based on a twin-screw extruder from the Nextmover MD 75/24 series, on which a specially designed stainless-steel head is installed. The cooling and calibration benches are designed with a unique idler system to reduce the overall dimensions of the line. In particular, ad-hoc idler systems allow for a threefold increase in the time the tube remains under water, thus ensuring greater efficiency and extrusion speed, with an unrivalled final tube quality.
In this respect, compliance with tolerances, which are particularly tight in the medical sector, is guaranteed by a sophisticated detection system that accurately measures the following parameters: diameter, ovality and wall thickness by laser and ultrasound, cross-section, shape and capacity of the tube, making it possible to rapidly reject non-compliant extrusions.
Another distinctive feature is the Haul-Off Unit, which is equipped with a Control Panel that, when fitted with the detection system, displays speed, measurement data and tolerances on the tube and its alarm systems. Furthermore,brushless motors, on request, help ensure even greater pulling accuracy for complete control of tube tension. Two types of accessories complete the line: the quick cutting system or the automatic winders, whose speed is precisely controlled throughout the winding process.
“The construction of an extrusion line for medical products is always a very challenging project, especially when installing in limited spaces and it is necessary to downsize the plant compared to standard sizes,” states Giovanni Bausano, Head of the Technical Department, adding “Thanks to decades of experience, Bausano is able to respond with cutting-edge technological solutions to the most complex technical specifications, in full compliance with strict international standards” and concludes “In this sense, the new high-speed line is an example of excellence, especially in terms of component customisation, including the Industry 4.0 software, which can be configured in the language of the end customer”.
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