FV400+HP corrugator

Itib Machinery started developing the HP range of corrugators in 2018 with its now best seller FV200HP and it was followed by the smaller FV32HP in 2023, targeting 80 m/min speed with electrical conduits. Until today, almost sixty FV200HP have been sold or delivered for cable ducting, drainage or controlled mechanical ventilation (CMV) applications.

We are proud to say that our FV200HP in both its short and long version, is today recognized as the best corrugator in its range available on the market. The success gained by this model pushed us to take a further step, developing a bigger corrugator offering the same or even improved technical solutions as the smaller FV200HP.  So, a newcomer will join the HP range at K 2025: our new FV400+HP!

The new corrugator has the aim to bridge cable ducts and drainpipes, covering a wide range of sizes from 90 mm OD up to 400 mm ID. The choice to include the ID, going above 400 mm OD, is highlighted by the “+” sign. Some more space in mould dimensions and an optional kit in the corrugator will allow the production of pipes with in-line socketing as well. The range is from 3” ID up to 15” ID for Countries based on imperial sizes like USA. One of the main technical features of the new equipment is the possibility to use the same moulds and tools of the FV200HP, giving customers great production flexibility. As said, all the most updated solutions already used in the smaller model are also available in the FV400+HP. Optimized moulds path for a smooth running of the carriers, fundamental for limited wear of the parts; the carriers are on rollers and running in channels machined in the two hardened steel main tables. Optimized forming channel, as long as possible for maximum cooling with the same total chain length; the FV400+HP comes only in the version with 50 pairs of moulds for maximum output. Individual mould cooling for a uniform temperature of the pipe, meaning constant mechanical properties of the same in all its length. Controlled motor torque transmission to prevent moulds damaging in case of emergency stop; the mould chain is moved by an a.c. motor with gearbox and two automatic clutches detect any motor load exceeding the set; in this undesired condition the corrugator moves back, far from the extruders, moved by an electrical motor. The well-known open construction makes all the parts visible and under control. The water-cooling hoses are fixed to a metal chain and located above the running path, avoiding any friction with metal surfaces; this solution translates to a long lifetime, limited leakages and reduced maintenance. The water rotating distributor is following the hoses in their rotation and moves on sturdy rails with bearing and shock absorbers at the two ends. The vacuum forming cannot be missing; it is located in the upper surface of the moulds to avoid moisture and oil suction with a great benefit for vacuum pump and filter. An oil-sealed rotary vacuum pump is included in the supply; it runs controlled by an inverter for power and energy saving. The vacuum bar descends automatically to the right level depending on the mould size; the operator can fix it on the touch screen during the machine set-up and automatically the bar moves to the right position. Some technical solutions which are an option on FV200HP are standard on the FV400+HP. The temperature of the moulds can be set and controlled; a solution that is sometimes necessary to have full control and get the optimal material distribution along the pipe profile. All the movements of the corrugator are by motors like up/down and left/right adjustment. To prevent interference and damage of moulds and dies, the operator fixes the zero position of the corrugator at the end of the centering and aligning procedure; a maximum displacement of the equipment can be set, before an alarm advises the potential risk of collision. Attention to safety for the operator in any working condition and situation is carefully considered as well; the corrugator is fully protected by a metal net structure with safety microswitches on sliding doors, where access to moulds is necessary during start-up and moulds replacement. A simple, complete and intuitive HMI guarantees full control of the equipment and running conditions.

The new corrugator will come with a new look as well; the famous great attention to details of ITIB MACHINERY is also in colors. An elegant combination of orange and gray identifying the company will be used in the machine, giving it a modern look and making it easily recognizable once in the production hall. The high potential of FV400+HP would be useless without a die-head and die-set which are designed to guarantee a perfect flow of the melt. The time to set up the extrusion line when changing the pipe diameter can be reduced by replacing the mouth-pieces and cooling mandrel only in case of DWP or removing the full one-piece die-set fixed to a fast change flange.

Once the maximum output is guaranteed by an efficient die-head, the super-efficient cooling of FV400+HP is supported by an additional cooling tank with puller. All made in stainless steel, complete of recycling pump, dryer with blower and heat exchanger to work in a closed loop, it comes in three, four- or six-meters length depending on space availability. A puller is fixed at its outlet to help to pull the pipe through the tank; its speed is of course synchronized with the corrugator. The flexible or rigid pipe can be coiled or cutted in bars by some additional down-stream equipment.

Of course, R&D activity of ITIB MACHINERY cannot stop and will cover soon the gap between F32HP and FV200HP. In fact, a growing demand of double wall pipes in small sizes requests and justifies a dedicated corrugator running at the fastest speed for production cost reduction and production lines optimization. The next PLAST 2026 show has been chosen as the best event to introduce the new HP marvel to the market. 

Stay tuned and see you soon at K 2025 in hall 15, booth D37!