Apa yang Menjadikan Pengurangan Kos Paip PVC Sangat Sukar?

Margins in the conduit business are getting tighter. Raw material costs continue to rise, while customer pricing keeps getting more competitive. For many manufacturers, the first ideas are: Use lower-cost raw materials, increase filler loading, or reduce certain additive levels. But reducing PVC pipe costs is not simply about lowering the price of one raw material. If the cost comes down but you also get: Failed compression or bending performance More die build-up Unstable extrusion More trial runs Higher scrap and downtime costs the savings from raw materials can quickly be offset by production losses. So, at the beginning of this project, we set several clear targets: Can the formulation cost be reduced by around 20%? Can compression and manual bending performance still meet GB requirements? Will die build-up increase after adjusting the lubrication system? How many production trials will be needed to validate the solution? These were the key questions behind the project.

Apa yang Akhirnya Dihantar?

Deliverable What It Included Customer Value Lubrication system review Analysis of the existing system and optimization opportunities Clearer direction for formulation adjustment Multiple cost calculations 3 candidate solutions and cost comparison per ton Understand the cost-saving potential before production trials Reference formulation + quotation Recommended ratio, dosage and product pricing Easier evaluation of the proposed solution Trial-by-trial sample support Samples provided according to each trial stage Less unnecessary sample use On-site technical support Analysis and adjustment during each production trial Less repeated trial-and-error Final production formulation Final formulation, processing parameters and test records A documented basis for scale-up and production The project schedule was determined according to the actual trial progress rather than a fixed timeline. The principle is simple: Every trial should have a clear objective, and every adjustment should be supported by actual test results.

Rumah > Berita > Berita Industri > Jimat Sekitar 20% Setiap Tan — Sambil Mengekalkan Prestasi Paip pada Spec

2026-09-25

Jimat Sekitar 20% Setiap Tan — Sambil Mengekalkan Prestasi Paip pada Spec

Q: Mengapa Poliester Wax + Poliester Homopolimer?

Comparison Conventional Microcrystalline Wax + OPE Wax Polyester Wax + Polyester Homopolymer Lubrication characteristics Mainly external lubrication Supports both internal and external lubrication needs Adjustment Mainly through total dosage Both ratio and total dosage can be adjusted PVC system matching Relies more on dosage adjustment Can be further tuned through the blend Die build-up control Influenced by wax type and dosage Can be optimized through the blend ratio Formulation flexibility Relatively limited More room for ratio adjustment In simple terms: The goal was not simply to find a cheaper wax, but to find a new lubrication balance through the combined system.

Kes Pengurangan Kos Pelinciran Konduit PVC

Rallychem Polyester Wax + Polyester Homopolymer Lubrication System

1. Apakah yang Membuatkan Pengurangan Kos Paip PVC Sangat Sukar?

Margin dalam perniagaan saluran semakin ketat.

Kos bahan mentah terus meningkat, manakala harga pelanggan terus menjadi lebih kompetitif. Bagi kebanyakan pengeluar, idea pertama ialah:

Gunakan bahan mentah berkos rendah, tingkatkan pemuatan pengisi atau kurangkan tahap aditif tertentu.

Tetapi mengurangkan kos paip PVC bukan sekadar menurunkan harga satu bahan mentah.

Jika kos turun tetapi anda juga mendapat:

Prestasi mampatan atau lentur yang gagal
Lebih banyak binaan mati
Penyemperitan tidak stabil
Lebih banyak percubaan dijalankan
Kos sekerap dan masa henti yang lebih tinggi

penjimatan daripada bahan mentah dengan cepat boleh diimbangi oleh kerugian pengeluaran.

Jadi, pada permulaan projek ini, kami menetapkan beberapa sasaran yang jelas:

Bolehkah kos formulasi dikurangkan sekitar 20%? Bolehkah prestasi mampatan dan lenturan manual masih memenuhi keperluan GB? Adakah binaan mati akan meningkat selepas melaraskan sistem pelinciran? Berapa banyak percubaan pengeluaran yang diperlukan untuk mengesahkan penyelesaian?

Ini adalah soalan utama di sebalik projek itu.

2. Langkah Pertama: Cari Di Mana Rumusan Sebenarnya Boleh Dioptimumkan

Apabila sasaran pengurangan kos ditetapkan, tindak balas pertama selalunya:

Bahan mentah mana yang mahal? Mari kita menggantikannya.

Tetapi pengurangan kos formulasi bukan sekadar mencari bahan yang lebih murah.

Untuk formulasi saluran PVC, struktur kos boleh dibahagikan secara kasar seperti berikut:

Item Kos	lebih kurang Bahagian Kos Penggubalan*	Pertimbangan Pengoptimuman
resin PVC	50–65%	Bilik terhad untuk pengurangan langsung; penggantian pengisi perlu dipertimbangkan
Kalsium karbonat	15–25%	Pilihan penjimatan kos yang agak langsung, tetapi terhad oleh prestasi pemampatan, lenturan dan pemprosesan
Penstabil haba	5–10%	Bilik pengurangan terhad; kestabilan haba mesti dikekalkan
Sistem pelinciran	1–2%	Bahagian kos yang kecil, tetapi menjejaskan pemplastikan, aliran dan pembentukan mati
Pigmen & lain-lain	1–3%	Bilik terhad dan sering terikat dengan keperluan penampilan

*Julat industri ilustrasi. Perkadaran sebenar berbeza mengikut rumusan.

Berikut adalah satu perkara yang mudah diabaikan:

Sistem pelinciran mungkin mewakili hanya sebahagian kecil daripada kos penggubalan, tetapi ia boleh menjejaskan jumlah ruang yang anda perlukan untuk melaraskan komponen lain.

Contohnya:

Meningkatkan CaCO₃ memerlukan pemplastikan yang stabil dan aliran cair;
Melaraskan tahap penstabil memerlukan pemprosesan yang mencukupi dan kestabilan haba;
Meningkatkan kecekapan pengeluaran memerlukan kawalan ke atas binaan cetakan dan turun naik penyemperitan.

Jadi, sistem pelinciran mungkin bukan tempat anda paling menjimatkan wang secara langsung, tetapi ia boleh menjejaskan keseluruhan ruang pengurangan kos formulasi.

Itulah sebabnya projek ini tidak bermula dengan hanya mencari bahan mentah yang lebih murah. Kami bermula dengan mengkaji semula keseimbangan pelinciran.

3. Ia Bukan Semata-mata Mengenai Menggantikan Lilin — Ia Mengenai Mengimbangi Semula Sistem Pelinciran

Dalam penyemperitan PVC, pelinciran dalaman dan luaran perlu kekal seimbang.

Hanya menukar jumlah tahap aditif boleh mencipta masalah baharu dengan mudah:

Pelarasan	Kemungkinan Isu
Pelinciran dalaman yang tidak mencukupi	Pemplastikan perlahan, tork yang lebih tinggi
Pelinciran dalaman yang berlebihan	Pemplastikan yang lebih cepat, suhu cair yang lebih tinggi
Pelinciran luaran yang tidak mencukupi	Lekatan dan peningkatan binaan acuan
Pelinciran luaran yang berlebihan	Masalah gelinciran, garisan kimpalan dan prestasi lenturan yang berkurangan

Untuk projek ini, kami menerima pakai:

Poliester Wax + Poliester Homopolimer Sistem Pelinciran

Objektifnya adalah untuk memadankan semula baki pelinciran formulasi sedia ada.

Mengapa Poliester Wax + Poliester Homopolimer?

Perbandingan	Lilin Mikrohablur Konvensional + Lilin OPE	Poliester Wax + Poliester Homopolimer
Ciri-ciri pelinciran	Terutamanya pelinciran luaran	Menyokong keperluan pelinciran dalaman dan luaran
Pelarasan	Terutamanya melalui jumlah dos	Kedua-dua nisbah dan jumlah dos boleh diselaraskan
Padanan sistem PVC	Lebih bergantung pada pelarasan dos	Boleh ditala lagi melalui adunan
Die build-up control	Influenced by wax type and dosage	Can be optimized through the blend ratio
Formulation flexibility	Relatively limited	More room for ratio adjustment

Secara ringkas:

The goal was not simply to find a cheaper wax, but to find a new lubrication balance through the combined system.

4. Calculate First, Then Run the Machine: Reducing Trial-and-Error

Production trials usually cost much more than the samples themselves.

That is why Rallychem did not simply send samples and ask the customer to run repeated trials. We followed a structured process.

01 | Information Confirmation

We collected:

Existing formulation
Extrusion process
Equipment and tooling information
Production output
Required GB performance standards
Heavy calcium carbonate sample

02 | Formulation Design

Based on the customer’s existing system, we developed Poliester Wax + Poliester Homopolimer formulation options.

At the same time, we provided:

Multiple candidate formulations
Product pricing
Cost calculation per ton of finished formulation
Evaluation against the target cost

03 | Solution Review

We shared the reference formulations, product quotations and cost calculations with the customer.

The solution was reviewed first to confirm that it was worth moving forward before samples were tested.

04 | Sample Delivery

Once the solution was confirmed, we provided the corresponding:

Polyester Wax + Polyester Homopolymer samples.

05 | Trial by Trial

The first production trial focused on:

Extrusion flow
Die build-up
Pipe appearance
Compression performance
Manual bending performance

Based on the results, the blend ratio was adjusted and further trials were carried out in the second and third rounds.

06 | Formulation Finalization

Once the solution met the project requirements for:

cost + processing stability + pipe performance + die build-up control

the final formulation was confirmed and prepared for production.

5. What Was Ultimately Delivered?

Deliverable	What It Included	Customer Value
Lubrication system review	Analysis of the existing system and optimization opportunities	Clearer direction for formulation adjustment
Multiple cost calculations	3 candidate solutions and cost comparison per ton	Understand the cost-saving potential before production trials
Reference formulation + quotation	Recommended ratio, dosage and product pricing	Easier evaluation of the proposed solution
Trial-by-trial sample support	Samples provided according to each trial stage	Less unnecessary sample use
On-site technical support	Analysis and adjustment during each production trial	Less repeated trial-and-error
Final production formulation	Final formulation, processing parameters and test records	A documented basis for scale-up and production

The project schedule was determined according to the actual trial progress rather than a fixed timeline.

The principle is simple:

Every trial should have a clear objective, and every adjustment should be supported by actual test results.

6. Why Rallychem?

01 | From Product Selection to Formulation Optimization

We look beyond the performance of a single wax.

The key question is what happens when it is introduced into the customer’s existing formulation and how the overall lubrication system changes.

That means considering:

Existing formulation + processing conditions + performance requirements + cost target

before deciding where to optimize.

02 | Experience with Polyester Wax + Polyester Homopolymer Systems

For different PVC pipe and profile applications, the blend ratio can be adjusted according to the existing formulation, equipment and performance requirements rather than simply applying a fixed dosage.

03 | Cost and Performance Are Evaluated Together

Each production trial focuses on:

Cost | Compression | Bending | Die Build-up | Extrusion Stability

Cost reduction is not evaluated by raw material price alone. The final solution also needs to work consistently in production.

04 | One Supplier for the Complete Blend

Both the Polyester Wax and Polyester Homopolymer are supplied by Rallychem.

This reduces coordination between multiple suppliers during formulation development and project implementation.

7. Want to Know How Much Your PVC Formulation Could Save?

If you are also working on PVC pipe cost reduction, you do not need to start with a production trial.

Share your current formulation and requirements with us, and Rali Chem can first evaluate the cost and potential optimization options based on your existing information.

Calculate first. Decide after.

Contact the Rallychem technical team to explore where your formulation still has room for optimization.

Prev：CPVC Pipe Flow Marks and Scorching After Resin Replacement: How to Troubleshoot Extrusion Problems?

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