Complete Turnkey Solution for Single Wall and Double Wall Corrugated Pipes
A complete turnkey corrugated pipe line comprises an extruder, die head, corrugator, die moulds, cooling tank, puller and coiler – supplied, integrated, installed, commissioned and supported as one package.
When it comes to manufacturing corrugated pipes, businesses require a comprehensive and reliable solution that ensures both efficiency and quality. ITIB India stands at the forefront of the industry, offering a complete turnkey solution for Single Wall and Double Wall corrugated pipe production. With cutting-edge equipment, precision engineering, and a commitment to delivering outstanding results, ITIB India provides manufacturers with everything they need to succeed.
This guide walks through each component in the line, what to specify at every stage, and how to match a corrugator model to the pipe range and output your order book demands.
The Key Components of ITIB India’s Turnkey Solution
ITIB India’s turnkey solution for corrugated pipes includes the following essential components, integrated in sequence from raw resin to finished coil.
1. Extruder
At the heart of any corrugated pipe manufacturing line is the extruder. We provide extruders designed for optimal performance, ensuring consistent and smooth extrusion of thermoplastics. These extruders feature advanced control systems that allow precise temperature management and material feed, resulting in high-quality pipes with uniform thickness and durability.
What to specify: screw diameter and L/D ratio against your target throughput, and barrel configuration against the polymer you will run most – PVC, PP, PE, PA and EVA each impose different melt handling requirements.
2. Die Heads
Die heads are responsible for shaping the plastic material into the desired pipe form. Our die heads are engineered to provide optimal material flow and uniform distribution, ensuring the production of high-quality pipes. These die heads are designed for easy maintenance and quick changeovers, reducing downtime and enhancing productivity.
What to specify: the number of diameter changeovers you expect per week. Frequent size changes justify a quick-change die head configuration, because changeover time is lost production time.
3. Corrugator
The corrugator is critical in forming the corrugated structure of the pipe, which provides flexibility and strength. ITIB India’s corrugators are engineered for efficiency, delivering high-speed production while maintaining precise control over pipe dimensions. These machines produce both single wall and double wall corrugated pipes, making them versatile across applications from drainage systems to electrical conduits.
The corrugators machine is the component that determines your diameter ceiling and your line speed. Everything upstream and downstream is sized around it. See the single wall corrugated pipe making machine and double wall corrugated pipe making machine ranges, or the model comparison in the next section.
4. Die Moulds
Precision is key in the manufacturing of corrugated pipes, and ITIB India’s die moulds are designed for the highest dimensional accuracy of the final product. These moulds are crafted to produce pipes with consistent wall thickness, diameter and corrugation profile. ITIB India offers a wide range of die moulds to accommodate different pipe sizes and specifications, ensuring versatility in production capabilities.
Vacuum requirement: critical shapes require a vacuum system to hold profile accuracy — specifically small diameters and uneven profile diameters. ITIB’s V-range machines accept an optional vacuum pump, with pumping capacity from 150 m³/h on the Form 15 series up to 300 m³/h on the Form 75 series.
What to specify: mould count. More moulds in the chain means a longer forming zone, which means higher achievable line speed at the same cooling quality. This is the single biggest lever on output — a Form 15-110 carries 110 moulds against the Form 15-70’s 70, and produces roughly 60% more PVC per hour at the same diameter range.
5. Cooling Tanks
Effective cooling is crucial to maintaining the structural integrity of the pipes. We can provide state-of-the-art cooling tanks that rapidly and evenly cool the extruded pipes, ensuring that they retain their shape and strength. These tanks are designed to maximise cooling efficiency while minimising energy consumption, making the production process more cost-effective.
What to specify: chilled water capacity against line speed. ITIB corrugators operate on cooling water at 6–8 °C; undersized chiller capacity caps your line speed regardless of what the corrugator is rated for.
6. Puller
The puller draws the pipe through the manufacturing process, ensuring smooth and consistent production. We provide pullers designed for accuracy and stability, maintaining correct tension on the pipes as they move through the corrugator. This results in a uniform corrugated structure and prevents distortion during the cooling process.
What to specify: tension control range matched to your thinnest wall section. Thin-wall small-diameter pipe is the condition where puller tension errors show up first as profile deformation.
7. Coilers
Once the pipes have been extruded and cooled, they need to be coiled for handling and storage. ITIB India’s coilers are built to handle pipes of various sizes and lengths, ensuring a smooth and efficient coiling process. These machines minimise manual handling, improving safety and reducing labour costs in the production facility..
Verified coiler specification:
| Parameter | Value |
| Standard pipe diameters | 6–60 mm |
| Winding width | 200–250 mm |
| Maximum winding speed | 300 rpm |
| External coil diameter (max) | 650 mm |
| Internal coil diameter | 250 mm |
| Installed power | 0.5 HP |
| Supply | 220 V single phase, 50 Hz |
| Options | Connection to cutting machine, pipe-guide |
Matching the Corrugator to Your Pipe Range
The corrugator model sets your commercial envelope – which pipe sizes you can quote for and how much you can produce per shift. The table below compares the full ITIB range against verified datasheet specifications.
| Model | Type | Min. I.D. | Max. O.D. | Moulds | Max. speed | PVC output | PP / HDPE output | Installed power |
| Form 15-70 | Single wall | 4.5 mm | 15 mm | 70 | 40 m/min | 33 kg/hr | 23 / 23 kg/hr | 1.5 kW |
| Form 15-110 | Single wall | 4.5 mm | 15 mm | 110 | 40 m/min | 53 kg/hr | 35 / 35 kg/hr | 1.5 kW |
| Form 32-52/72 | Single wall | 10 mm | 32 mm | 52 (ext. 72) | 35 m/min | 115 kg/hr | 65 / 65 kg/hr | 4.0 kW |
| Form 32-72/92 | Single wall | 10 mm | 32 mm | 72 (ext. 92) | 35 m/min | 150 kg/hr | 80 / 80 kg/hr | 4.0 kW |
| Form 65-54/74 | Single wall | 10 mm | 65 mm | 54 (ext. 74) | 27 m/min | 140 kg/hr | 80 / 80 kg/hr | 3.0 kW |
| Form 75-64 | Double wall | 30 mm | 75 mm | 64 | 25 m/min | – | 115 / 115 kg/hr | 5.5 kW |
| Form 75-96 | Double wall | 15 mm | 75 mm | 96 | 25 m/min | – | 260 / 115 kg/hr | 5.5 kW |
Output figures carry a ±10% tolerance. ITIB reserves the right to modify machine specifications without prior notice.
How to read this table
- Diameter first, output second. Pick the models that cover your required diameter band, then compare output within that shortlist. A machine that cannot make your product is not cheaper at any output rate.
- Mould count is the output lever. Within a series, the higher mould count buys throughput at the same diameter range – Form 15-110 over Form 15-70, Form 32-72/92 over Form 32-52/72.
- Extendable mould chains protect the investment. The Form 32 and Form 65 series ship at one mould count and extend to a higher one, so capacity can be added without replacing the machine.
- PVC runs faster than polyolefins. Across every single wall model, PVC output is roughly 1.4 – 1.8× the PP and HDPE figure. Size the line against the material you will actually run in volume.
Application-specific lines
ITIB builds dedicated lines tuned to the size range and specification of each end use: electrical conduits, telecom ducts, medical tubes, sanitary pipes, harness pipes and washing machine pipes.
Why Choose ITIB India’s Turnkey Solution?
With ITIB India’s complete turnkey solution, manufacturers can streamline their corrugated pipe production process from start to finish. The seamless integration of each component ensures maximum efficiency, minimal waste and consistent product quality. Whether you are producing pipes for drainage, sewage, electrical, automotive, sanitary or telecommunications applications, ITIB India’s advanced technology and engineering expertise offer proven reliability and performance.
As part of the global ITIB Group, ITIB Machinery India Pvt. Ltd. brings over five decades of European corrugator engineering to the Indian market, with machines designed in collaboration with ITIB’s international R&D centres.
Benefits of ITIB India’s Turnkey Solution
- End-to-end integration: Each piece of equipment is synchronised to work in tandem, reducing the risk of errors and downtime.
- Customisable solutions: ITIB India offers equipment for various pipe sizes and materials, allowing manufacturers to tailor production lines to specific needs.
- Energy efficiency: With advanced cooling systems and optimised machinery, ITIB India helps manufacturers reduce energy consumption and operational costs.
- High-quality output: Precision engineering ensures every pipe produced meets industry standards for strength, flexibility and durability.
- Single point of accountability: One supplier for the full line means no interface disputes between vendors when commissioning.
- Complete range under one roof: From the compact Form 15-70 to the high-capacity Form 75-96, combined with coilers for a genuine end-to-end solution.
How the Turnkey Project Runs
ITIB India’s turnkey approach covers everything required to get a corrugated pipe production line operational:
- Consultation and needs assessment – Our engineers assess production volume targets, pipe specifications, material requirements and facility constraints.
- Plant layout design – We design the production floor layout to maximise throughput and operator efficiency.
- Equipment supply – All line components, from extruder to coiler, supplied by ITIB India with full warranty coverage.
- Installation and commissioning – Our technical team handles on-site installation, system integration and commissioning.
- Operator training – Hands-on training covering machine operation, maintenance procedures and troubleshooting.
- After-sales support – Ongoing technical support, spare parts supply and process optimisation assistance.
For full specifications and configuration options, see the corrugated pipe production line page.
Conclusion
ITIB India provides a complete, high-performance solution for single wall and double wall corrugated pipe manufacturing. From the extruder to the coiler, each component is designed with efficiency, reliability and quality in mind. By choosing ITIB India’s turnkey solution, manufacturers can enhance their production processes, reduce costs and deliver top-tier products to their customers.
Ready to specify a line? Contact India’s trusted corrugator machine manufacturer at sales@itibindia.com or +91-22-62231691 / +91-96191-40918, or use our contact form.
Frequently Asked Questions
What does a complete corrugated pipe production line include?
A complete line from ITIB India includes the extruder, die head, corrugator, die moulds, cooling tanks, puller and coiler. All components are integrated and optimised for your specific pipe specifications and production volume.
What pipe sizes can an ITIB turnkey line produce?
Depending on the corrugator model selected, ITIB production lines produce single wall pipes from 4.5 mm I.D. up to 65 mm O.D. and double wall pipes from 15 mm I.D. up to 75 mm O.D.
Which ITIB corrugator gives the highest output?
The Form 75-96 double wall corrugator delivers up to 260 kg/hr in PP. Among single wall models, the Form 32-72/92 delivers up to 150 kg/hr in PVC.
What materials can ITIB corrugator lines process?
ITIB lines process PE, PP, PVC, PA, EVA and other thermoplastic materials.
When is a vacuum system required on a corrugator?
A vacuum system is required for critical shapes – small diameters and uneven profile diameters – where it holds the profile accurately during forming. It is available as an option on ITIB V-range machines, with pumping capacity from 150 m³/h to 300 m³/h depending on model.
Can ITIB India set up a corrugated pipe plant from scratch?
Yes. ITIB India provides turnkey project solutions covering plant layout design, equipment supply, installation, commissioning and operator training.
Does ITIB India provide after-sales support?
Yes. ITIB India provides ongoing technical support, spare parts supply and process optimisation assistance.
Implementation Notes (do not publish)
Positioning change – read first
This post previously duplicated /corrugated-pipe-production-line/ almost section for section. The refresh repositions it as a specification and selection guide so it stops competing with the money page and starts feeding it.
| Money page /corrugated-pipe-production-line/ | This blog post | |
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| Owns | corrugated pipe production line, turnkey corrugated pipe plant | how to select a corrugator machine, corrugator machine specifications, corrugator output kg/hr, corrugator mould count |
| Unique asset | Turnkey process, industries served | Verified 7-model spec comparison table |
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