El calentamiento geotérmico en interiores, más comúnmente llamado calefacción de suelo, se ha convertido en la solución de confort predeterminada para apartamentos residenciales, villas, escuelas, hospitales y edificios comerciales ligeros en Europa, Asia Central y Asia Oriental. El tubo que transporta agua caliente a través del hormigón no es ya un tubo de polietileno simple. Las especificaciones modernas exigen una capa de barrera al oxígeno que impida que el oxígeno disuelto entre en el circuito, porque el oxígeno en el agua acelera la corrosión de los componentes metálicos del sistema de calefacción.Equipo de extrusión de precisión de tubería de calefacción geotérmica con barrera al oxígeno para la instalación de tuberías de calefacción geotérmica en interiores. is therefore a precision multi-layer co-extrusion system, not a simple single-material pipe line. Faygo, a Wanplas factory with 22 years of dedicated experience in plastic pipe and profile extrusion, designs and builds the multi-layer co-extrusion lines that produce oxygen barrier PE-RT floor heating pipe for indoor geothermal heating pipeline installation. Operating three specialized factories, including the FAYGOPLAST facility in Zhangjiagang City covering 26,650 square meters and only two hours from Shanghai Airport, and holding 13 national patents with 8 invention patents, Faygo delivers CE and ISO certified equipment together with complete turnkey solutions to customers in dozens of countries. This article explains the structure and standards of oxygen barrier floor heating pipe, the material system behind PE-RT and EVOH, the architecture of a precise five-layer co-extrusion line, the Faygo line configurations available, and the process, quality and service framework that keeps a production line running to specification for years.
The central engineering problem of this product is not melting polyethylene. It is holding a very thin, moisture-sensitive ethylene vinyl alcohol copolymer layer exactly where it belongs, at a stable thickness, through a high-speed continuous extrusion process, while three or four other melts flow around it without disturbance. Get that right and the pipe passes the oxygen permeability limit with margin and a long service life. Get it wrong and the barrier layer breaks, delaminates or disappears, and the pipe fails its most important function. The remainder of this article is a practical, equipment-focused guide to achieving that control.
Estructura de tubería de barrera al oxígeno y normas aplicables.
An oxygen barrier floor heating pipe is defined by what you cannot see: the thin functional layer of EVOH (ethylene vinyl alcohol copolymer) that stops oxygen diffusion. The pipe only works as a system, so the producer must control the whole stack of layers, not just the base polymer. The industry has settled on two practical constructions, and choosing between them is the first decision a line buyer makes.
The five-layer structure and the three-layer alternative
The five-layer (often written 5-layer) structure, from the inner bore outward, is PE-RT base pipe, tie layer, EVOH oxygen barrier layer, tie layer and an outer PE protection layer. The two tie layers are adhesive resins that bond the non-polar polyethylene to the polar EVOH so the barrier layer cannot peel away. The outer PE layer shields the EVOH from scratches, UV and mechanical abuse during coiling, transport and installation.
La estructura de tres capas (3 capas) colapsa la pila en PE-RT, una capa adhesiva combinada más una barrera de EVOH y una capa exterior de PE. En algunos diseños, el EVOH se co-extruye con un adhesivo integrado, por lo que solo se forman tres capas físicas. El diseño de tres capas utiliza menos extrusoras, una cabeza de co-extrusión más simple y un menor coste de equipo, mientras que el diseño de cinco capas ofrece la protección de barrera más robusta y la mejor defensa contra los daños provocados por el manejo.
Both constructions must meet the same oxygen permeability limit. The layer count is an equipment and durability choice, not a compliance shortcut.
Oxygen permeability requirement and governing standards
El número decisivo de rendimiento es la permeabilidad al oxígeno. Para la tubería de calefacción geotérmica con barrera al oxígeno, el requisito es una permeabilidad al oxígeno de 0,32 mg por metro cúbico por día o inferior, medida a 40 grados Celsius, según el método DIN 4726. Este límite existe porque el oxígeno que se difunde a través de la pared del tubo en el agua reacciona con componentes de acero, latón y aluminio, como colectores, válvulas, bombas y radiadores, acelerando la corrosión y reduciendo la vida útil del sistema.
Several standards frame the product and the line that makes it. GB/T 28799 covers polyethylene of raised temperature resistance (PE-RT) piping systems for hot and cold water installations. ISO 22391 covers PE-RT piping systems for hot and cold water installations. DIN 4726 specifies requirements and test methods for plastic piping systems used in floor heating and radiator connection, including the oxygen permeability limit. ASTM F2623 covers test methods for determining the oxygen gas transmission rate of polyethylene pipe and tubing. These standard names appear in plain text only; the article contains no linked references. A production line is judged by its ability to make pipe that passes all of them consistently, not once but across every coil of every shift.
Material System for Oxygen Barrier Floor Heating Pipe
La selección del material determina la ventana de procesamiento, la velocidad de línea y el costo final. Tres familias de polímeros son importantes: PE-RT como base estructural, PEX como base reticulada principal y EVOH como barrera. Cada uno se comporta de manera diferente en el tambor y en la cabeza de la matriz.
Propiedades de PE-RT de tipo I y II
PE-RT (polyethylene of raised temperature resistance) is a specially nucleated, moderately crosslinkable polyethylene that keeps the ease of processing of a thermoplastic while gaining improved high-temperature performance. Type I and Type II are the two common grades for floor heating. The density sits in the range 0.933 to 0.947 grams per cubic centimeter. The melt flow rate at 190 degrees Celsius under 2.16 kilograms load is typically 0.5 to 1.0 grams per 10 minutes. The long-term service temperature is about 70 degrees Celsius with a short-term peak around 95 degrees Celsius, and the material sustains the required hydrostatic strength for the design life of the system.
Type II PE-RT offers a higher design stress and better high-temperature capability than Type I, which is why many modern floor heating coils specify Type II. From an extrusion standpoint both are processed as thermoplastics, so the line can run without the post-extrusion crosslinking step that PEX requires. That single fact is why PE-RT dominates oxygen barrier floor heating pipe production and why the co-extrusion line described here centers on PE-RT.
Alternativas de reticulación de PEX (a, b, c)
PEX (crosslinked polyethylene) is the long-established alternative base for floor heating pipe. The three crosslinking routes are PEX-a (peroxide crosslinking, highest crosslink degree, most uniform), PEX-b (silane or moisture crosslinking, good balance of cost and performance) and PEX-c (electron-beam or radiation crosslinking, precise control, no chemical crosslinker). All three deliver excellent high-temperature and pressure resistance, but PEX requires a crosslinking step after extrusion, which complicates the line and the quality chain. Because the oxygen barrier co-extrusion focus of this article is on PE-RT, PEX is noted for comparison only; the equipment described is built around thermoplastic PE-RT processing.
EVOH oxygen barrier layer and ethylene content
The oxygen barrier layer (EVOH) is an ethylene vinyl alcohol copolymer whose oxygen barrier performance comes from the hydrogen-bonded hydroxyl groups of the vinyl alcohol segments. The ethylene content is the key variable. At 32 mol percent ethylene, EVOH offers an excellent balance of barrier performance and processability, with enough flexibility and melt strength to form a continuous thin layer. At 38 mol percent ethylene, the barrier is slightly reduced but processability and moisture resistance improve, making it easier to handle and co-extrude at higher line speeds. The choice between 32 and 38 mol percent ethylene is a trade between maximum barrier and easier, faster processing.
El problema práctico predominante con el EVOH es la humedad. El EVOH es altamente higroscópico y absorbe agua del aire, y esa agua debe eliminarse antes de que el material entre en el barril. Un secador deshumidificador dedicado, dimensionado para el flujo de EVOH, es por lo tanto una parte obligatoria de la línea, no un accesorio opcional. El requisito de secado es una de las diferencias definitorias entre una línea de tuberías de barrera y una línea de tuberías de productos básicos.
Anatomía de una línea de coextrusión de múltiples capas de precisión.
A multi-layer oxygen barrier pipe line is a tightly synchronized chain of extruders, a co-extrusion die head, a vacuum calibration tank, a cooling section, a haul-off unit, a measurement station, a cutting or coiling unit and a centralized control system. Each station must be matched to the others or the thin barrier layer drifts out of tolerance.
Main extruder and barrier screw design
The main extruder Plasticizes the PE-RT base and forms the bulk of the pipe wall. A single-screw extruder with a length-to-diameter ratio in the range 30 to 33 is standard. The screw is a barrier screw, meaning it carries a secondary flight that separates molten material from solids, improving melt homogeneity and pressure stability. Stable melt pressure is the single most important condition for a stable barrier layer, because pressure fluctuation in any extruder translates directly into layer thickness variation. The main extruder barrel is heated in multiple independently controlled zones so the PE-RT melt reaches its window of roughly 200 to 230 degrees Celsius without hot spots.
Side extruders and co-extrusion architecture
A five-layer line uses two to four side extruders in addition to the main extruder. One small side extruder Plasticizes the EVOH barrier layer, two feed the tie layers, and a fourth may form the outer PE protection layer. A three-layer line needs fewer: one for the barrier and one for the combined adhesive, or a single barrier extruder with the adhesive metered inline. Each side extruder is smaller in screw diameter than the main unit, but each must hold its own melt pressure steady, because the barrier layer thickness is set almost entirely by the ratio of EVOH throughput to line speed.
Multi-layer co-extrusion die head
The co-extrusion die head is the heart of the line. Two geometries dominate. The spiral mandrel die builds each layer around a rotating helical channel and is excellent for round, symmetric pipes because it gives uniform circumferential distribution. The stacked or layer-by-layer die forms the layers in discrete annular plates and is easier to reconfigure for different layer counts. Both types must balance the flow of every melt so that the EVOH layer stays centered and the tie layers stay uniform around the full circumference. Flow balancing is done by adjusting restrictor rings and runner geometry, and it is verified by cutting samples and measuring layer thickness at multiple points around the cross-section.
Melt temperature window matching
The hardest part of oxygen barrier co-extrusion is matching the melt temperature windows of PE-RT and EVOH. PE-RT processes at roughly 200 to 230 degrees Celsius. EVOH processes at roughly 200 to 220 degrees Celsius. The windows overlap, but they are not identical, and the EVOH side is far less forgiving. If the two melts meet at the die head with a large viscosity gap, the thinner, higher-viscosity EVOH can be dragged, thinned or broken by the faster PE-RT flow. Matching the melt temperatures keeps both layers in a comparable viscosity range so the barrier layer stays continuous and centered. Temperatura de la cabeza de la matriz profiling, independent side-extruder barrel control and careful selection of EVOH grade are the tools that achieve this match.
Faygo Configuración de la líneas and Especificación Tables
Faygo offers its oxygen barrier capability on established product platforms rather than one-off machines. The two configurations below are built on the Faygo Línea de extrusión de tuberías PP-R/PE-RT and the Serie de núcleos de extrusión de tuberías Faygo, both of which are real Wanplas-group product lines used for pipe diameters from De 12 a 575 milímetros with wall thickness up to 6.5 millimeters. The tables list the parameters a buyer actually evaluates.
Línea de extrusión de tuberías Faygo PP-R/PE-RT, configuración de cinco capas de barrera al oxígeno.
This configuration is the standard choice for 16 to 32 millimeter PE-RT floor heating pipe with a full five-layer EVOH barrier. It pairs a 60 millimeter barrier-screw main extruder with dedicated side extruders for tie, EVOH and outer PE, and it is the configuration most floor heating coil producers start with because it delivers the most robust barrier at moderate output.
| Parámetro | Faygo Especificación |
|---|---|
| Applicable pipe diameter | 16 a 32 mm (tubo de calefacción de suelo PE-RT) |
| Main extruder screw diameter / L/D | 60 mm / 33:1 (barrier screw) |
| Side extruders (co-extrusion) | 1 x 30 mm (EVOH) + 2 x 25 mm (tie layers) + 1 x 30 mm (outer PE) |
| Capas de coextrusión | 5 (PE-RT / tie / EVOH / tie / PE outer) |
| Output | 60 a 120 kg/h |
| Line speed | 8 to 25 m/min |
| Potencia instalada | 145 kW |
| Sección de calibración y enfriamiento | vacuum calibration tank 6 m + spray cooling tank 12 m |
| Haul-off type | 2-caterpillar belt haul-off unit |
Serie de núcleos de extrusión de tuberías Faygo, high-output multi-layer configuration
For producers targeting higher hourly output on 16 to 25 millimeter pipe, the Serie de núcleos de extrusión de tuberías Faygo high-output multi-layer configuration uses a larger 75 millimeter main extruder and supports selectable three or five layers. This configuration raises line speed and output while keeping the same precision control philosophy, and it suits large floor heating coil manufacturers and exporters.
| Parámetro | Faygo Especificación |
|---|---|
| Applicable pipe diameter | 16 to 25 mm |
| Main extruder screw diameter / L/D | 75 mm / 33:1 (barrier screw) |
| Side extruders (co-extrusion) | 1 x 40 mm (EVOH) + 1 x 30 mm (compuesto adhesivo) + 1 x 30 mm (exterior) |
| Capas de coextrusión | 3 or 5 selectable |
| Output | 120 to 200 kg/h |
| Line speed | 12 a 40 m/min |
| Potencia instalada | 185 kW |
| Sección de calibración y enfriamiento | vacuum calibration tank 6 m + spray cooling tank 14 m |
| Haul-off type | 3-caterpillar belt haul-off unit |
Both configurations share the Faygo intelligent control system, which lets the operator set parameters freely and adjust them in real time, and both use internationally sourced electrical components for reliability. The choice between them is driven by target diameter, layer count and hourly output rather than by any difference in control philosophy.
Die Head and Control del espesor de capa
La cabeza del molde es donde se forma la capa de barrera, y el control del espesor de la capa es donde se resuelven la mayoría de los problemas de calidad. El objetivo es una capa de EVOH delgada, continua y centrada cuyo espesor se mantenga dentro de un intervalo ajustado durante toda la longitud del bobinado.
Control del espesor y la desviación de la capa de EVOH
The functional EVOH layer is typically held at 0.08 to 0.15 millimeter. Thinner than that risks discontinuity; thicker wastes an expensive material and slows the line. The engineering target is to hold the layer thickness deviation within plus or minus 10 percent, measured around the circumference and along the length. Deviation is controlled by stabilizing the EVOH extruder melt pressure, balancing the die head flow channels, and tuning the die lip adjustment. A small change in screw speed or melt temperature moves the layer thickness immediately, so the control system must treat the EVOH extruder as a precision metering device, not a rough feeder.
Interlayer adhesion and peel strength
Las capas de unión existen para unir el polietileno al EVOH, y su espesor y ubicación determinan la resistencia al desprendimiento intercapas. Si hay muy poca resina de unión, la barrera se desprende durante el enrollamiento o en el sitio de construcción; demasiado la aumenta el costo sin beneficio. La resistencia al desprendimiento se verifica mediante una prueba de desprendimiento por capas en una muestra de sección transversal, y es sensible a la correspondencia de la temperatura de fusión descrita anteriormente: cuando el PE-RT y el EVOH se unen a las temperaturas correctas y cercanas, la capa de unión humedece ambas superficies y se une bien. La cabeza de la matriz también debe mantener los presiones de fusión de las capas adyacentes cerca para que una capa no supere y adelgace a la siguiente.
Calibración al Vacío y Enfriamiento
Una vez que la masa fundida de varias capas sale de la cabeza del molde, debe congelarse con el diámetro y la redondez exactos antes de poder moverse. Esta es la función de la sección de calibración y enfriamiento, y es donde se establecen la ovalidad y la calidad de la superficie.
Calibration sleeve and vacuum level
El tubo se tira sobre un tubo de calibración, un tubo de precisión que establece el diámetro exterior. El material del tubo de calibración suele ser latón o acero inoxidable, con preferencia el acero inoxidable por su resistencia al desgaste y superficie limpia. Se extrae un vacío a través de las ranuras del tubo para tirar el fundido blando contra el orificio. El rango de vacío práctico es de -0,02 a -0,06 MPa. Si el vacío es demasiado bajo, el tubo no se ajusta; si es demasiado alto, la pared se sustrae o se marcan las superficies. El tanque de calibración de vacío contiene el tubo de calibración y el primer agua de enfriamiento, la más agresiva.
Temperatura del agua gradient and ovality
El enfriamiento se realiza en etapas como un gradiente de temperatura en lugar de un baño frío único. La primera sección funciona a una temperatura de 12 a 18 grados Celsius para establecer la forma rápidamente sin el choque térmico que podría fijar la tensión, y las secciones posteriores funcionan progresivamente más calientes para completar el enfriamiento de forma suave. La longitud de enfriamiento debe ajustarse a la velocidad de línea: a alta velocidad, el tubo necesita más longitud del tanque para alcanzar la misma temperatura final, o saldrá blando y ovalado. La ovalidad, la desviación de la sección transversal de un círculo verdadero, se controla mediante vacío estable, temperatura equilibrada del agua y un manguito de calibración en buen estado. Un tubo que sale del tanque ovalado permanecerá ovalado y puede fallar en las pruebas de dimensiones en el sitio de construcción.
Haul-Off, Measurement, and Coiling
The downstream end of the line measures, cuts or coils and packages the finished pipe. Precision here protects the investment made upstream.
Synchronization and online measurement
La unidad de extracción tira el tubo a la velocidad de línea exacta establecida por la salida del extrusor. Una unidad de extracción de gusanera utiliza cintas o almohadillas que sujetan el tubo sin aplastarlo, y su sincronización de velocidad con el extrusor y el cortador evita la variación del espesor y el defecto de la junta de bambú. La medición del diámetro en línea mediante láser proporciona el diámetro exterior en tiempo real, y el objetivo de tolerancia es más o menos 0,1 a 0,3 milímetro dependiendo del diámetro. La medición ultrasónica del espesor de la pared controla el espesor alrededor de la circunferencia sin cortar el tubo, detectando la excentricidad temprano. Un contador de metros registra la longitud para el etiquetado de bobinas o paquetes.
Metering and automatic coiling
El tubo de calefacción se entrega generalmente en bobinas en lugar de longitudes rectas, por lo que un enrollador automático enrolla el tubo a una longitud establecida y luego la unidad de corte lo corta de forma limpia. El enrollador debe enrollar sin arrugas ni sobretensiones, porque una arruguilla se convierte en un punto débil en el suelo. Sigue el embalaje, a menudo con una etiqueta impresa que contiene el material, el diámetro, la longitud y los marcadores estándar. Toda la secuencia posterior se vincula al sistema de control central, por lo que un cambio de velocidad en el extrusor se propaga instantáneamente a la unidad de extracción, el cortador y el enrollador.
Reference Process Parameters for Common Pipe Sizes
The table below gives reference process parameters for the most common oxygen barrier floor heating pipe sizes. These are starting points; every line is tuned to its own screw, die head and material batch. The temperatures are barrel zone settings feeding toward the die head, the vacuum and water values are the calibration and first cooling targets, and the output and line speed are the resulting operating point.
| Pipe size (mm) | Output (kg/h) | Line speed (m/min) | Barrel zone temp (deg C) | Die head temp (deg C) | Vacuum (MPa) | Cooling water (deg C) |
|---|---|---|---|---|---|---|
| 16 x 2.0 | 45 to 70 | 12 to 20 | 190 / 215 / 225 / 230 | 210 to 225 | -0.03 to -0.05 | 14 to 18 (1st), 20 to 30 (later) |
| 20 x 2.0 | 60 to 95 | 10 to 16 | 190 / 215 / 225 / 230 | 210 to 225 | -0.03 to -0.05 | 14 to 18 / 20 to 30 |
| 25 x 2.3 | 80 to 120 | 8 to 13 | 190 / 220 / 228 / 232 | 212 to 226 | -0.04 to -0.06 | 14 to 18 / 20 to 30 |
Los extrusores de EVOH y de lado funcionan a sus propios flujos más bajos, configurados para entregar el espesor de capa objetivo a la velocidad de línea elegida. Los operadores optimizan todo el conjunto juntos, porque cambiar la velocidad de línea sin reequilibrar los extrusores laterales es la forma más rápida de obtener una capa de barrera no conforme.
Quality Elemento de inspeccións
A compliant oxygen barrier pipe line is validated by a defined set of tests, run on samples taken from production. The table lists the standard inspection items and the acceptance the line must support.
| Test item | Condición | Aceptación |
|---|---|---|
| Hydrostatic test | 95 °C/1000 h | No failure, no leakage |
| Oxygen permeability | 40 deg C, DIN 4726 | 0.32 mg/(m3·d) or lower |
| Espesor de la capa | Microscopy cross-section | EVOH 0.08 to 0.15 mm, deviation within plus or minus 10 percent |
| Peel strength | Interlayer | No delamination |
| Reversión longitudinala | Per standard | 3 percent or lower |
| Velocidad de flujo del fundido | 190 deg C / 2.16 kg | 0.5 to 1.0 g/10min |
| Dispersión de negro de carbono | If applicable | Even, no agglomeration |
| Aspecto y ovalidad | Visual plus gauge | Smooth surface, ovality within tolerance |
The oxygen permeability test and the layer thickness microscopy are the two checks unique to barrier pipe; a commodity pipe line is not judged by them, which is why barrier production needs the extra control discipline described throughout this article.
Common Defects and Countermeasures
Even a well-designed line drifts. The table below maps the defects most specific to oxygen barrier co-extrusion to their usual cause and the corrective action, giving operators a fast reference.
| Defecto | Typical cause | Countermeasure |
|---|---|---|
| EVOH layer break or discontinuity | Melt pressure fluctuation, insufficient drying | Stabilize screw speed and melt pressure, dry EVOH, raise pressure margin |
| Interlayer delamination | Poor tie layer, temperature mismatch | Optimize tie layer thickness, match melt temperatures |
| Bamboo-joint surface pattern | Calibration or haul-off speed mismatch | Synchronize haul-off, tune vacuum and pull ratio |
| Ovalidad fuera de tolerancia | Unstable vacuum, uneven cooling | Adjust vacuum, balance water temperature gradient |
| Eccentricidad de la pared | Die centering offset | Ajuste los pernos de la lipa de la matriz, centre el mandril |
| Pitting en la pared interna | Humedad o gas, suciedad en la masa fundida | Materiales secos, matriz limpia, deshumidifique la EVOH |
| Color difference | Variación del masterbatch o del regrind. | Standardize color masterbatch, control regrind ratio |
| Bubbles in barrier layer | EVOH not dried | Dry EVOH to required moisture, preheat hopper |
La mayoría de estos defectos se deben a dos causas principales: presión de la masa fundida inestable y humedad en la EVOH. Una línea que controle esas dos variables con precisión evitará la mayoría de los fallos específicos de la barrera.
Floor Heating Engineering Side Requirements
The pipe line does not exist in isolation; it serves a building system with its own rules. The producer must understand the installation side because it drives the dimensional and coil requirements the line must meet.
The pipe is laid as a continuous coil in the screed, and the coil bending radius must be at least 5 times the pipe diameter (5D) to avoid kinking and to keep the wall stress within design limits. The construction temperature on site affects handling; very cold pipe becomes stiff and cracks if bent too sharply, so storage and lay-down conditions matter. The oxygen barrier exists specifically to protect the metal parts of the system, the manifolds, valves, pumps and mixing units, from corrosion caused by oxygen dissolved in the circulating water. A continuous, intact EVOH layer is what makes the 50-year system design life realistic, because without it the metal components would corrode long before the polymer pipe itself wore out. Producers who understand this relationship sell not just pipe but system reliability, and the line that makes a dependable barrier is the foundation of that promise.
Capacity, Energy Consumption, and Scrap Recycling
Beyond compliance, a buyer evaluates throughput, energy per kilogram and material economy. Output for the configurations above runs from 60 kg/h on the compact five-layer line to 200 kg/h on the high-output line, with the achievable number depending on diameter, wall thickness and layer count. Energy is usually expressed as kilowatt-hours per kilogram of good pipe, and it is minimized by right-sizing the extruders to the job, recovering heat where practical, and avoiding over-cooling that wastes chiller capacity.
Scrap is unavoidable at start-up and during grade changes, and a well-run line crushes start-up scrap and feeds it back. The rule for oxygen barrier pipe is strict: the online crushed regrind reuse ratio is controlled at 10 percent or lower, and EVOH layer scrap must never be mixed back into the polyethylene or tie layers. EVOH in the base resin would contaminate the melt, change the processing behavior and ruin the barrier. Clean separation of the barrier scrap from the structural scrap is therefore a non-negotiable part of the material handling design. Relative equipment and operating cost tiers for this category run from Medium for a basic three-layer line to High or Very High for a fully instrumented five-layer line with automatic thickness control, while the EVOH resin itself places the material cost at Premium compared with plain PE-RT.
Guía de selección: Ajustar el requisito a la configuración de Faygo.
La tabla siguiente convierte un requisito del comprador en una configuración recomendada de Faygo. Es un punto de partida para una cotización detallada; la selección final también depende de las condiciones de utilidad locales, el espacio disponible en el suelo y los estándares del mercado objetivo.
| Diámetro de la tubería | Layer structure | Target output | Configuración recomendada de Faygo |
|---|---|---|---|
| 16 a 20 mm | 5-layer | 60 a 120 kg/h | Línea de extrusión de tuberías Faygo PP-R/PE-RT, configuración de cinco capas de barrera al oxígeno. |
| 16 to 25 mm | 3 or 5-layer | 120 to 200 kg/h | Serie de núcleos de extrusión de tuberías Faygo, high-output multi-layer configuration |
| 20 to 32 mm | 5-layer, thicker wall | 80 to 150 kg/h | Faygo Línea de extrusión de tuberías PP-R/PE-RT with enlarged calibration and cooling |
| Trial or R and D small batch | 3 or 5-layer | Bajo | Serie de núcleos de extrusión de tuberías Faygo with lab-scale co-extrusion die head |
For producers who also run PPR or plain PE pipe, the same Faygo platforms switch between products by changing the die head and screw setup, which protects the original equipment investment and shortens the payback period. The Wanplas group can supply complementary downstream and auxiliary equipment for a complete plant where a broader product mix is planned.
Aplicaciones en diversos sectores industriales: La tubería de transición corrugada sólida sirve a cualquier red que mezcla una sección corrugada ligera con una unión sólida o un calibre diferente, lo que abarca la ingeniería municipal, la construcción de edificios, la agricultura y los servicios públicos. En los trabajos municipales, conecta tramos de HDPE de gran diámetro para gas y agua a cámaras y laterales; en la construcción, une tuberías de servicio de HDPE y PPR con accesorios y contadores; en la agricultura, ramifica las tuberías corrugadas de riego a manijas sólidas de goteo y aspersión; en las comunicaciones y la energía, conecta un conducto de protección de cables corrugados a un manguito de servicio sólido en el agujero de mano. Debido a que la línea es flexible en cuanto al material, ya que puede servir PE, PVC y PP, la misma plataforma puede servir a un contratista de drenaje por la mañana y a un proveedor de conductos de cables por la tarde, cambiando la herramienta y el calibre, por lo que Faygo comercializa la familia de extrusión de tuberías como una solución de infraestructura municipal y agrícola configurable en lugar de una máquina de un solo uso.
Oxygen barrier PE-RT floor heating pipe serves a wide set of real end products, and naming them helps a buyer see the market:
- Floor heating engineering – the primary market: coils laid in screed for residential apartments, villas, schools, hospitals and offices, delivering even, comfortable low-temperature radiation heat.
- Building water supply – warm and cold potable and circulating water lines where the barrier protects connected metal fittings and extends system life.
- HVAC (heating, ventilation and air conditioning) – low-temperature heating and cooling distribution loops, including radiant ceiling and wall systems that share the same pipe technology.
- Municipal and district heating – pre-insulated secondary network pipes where the barrier reduces corrosion of steel components in the energy station and manifold rooms.
- Irrigación agrícola – greenhouse and nursery heating loops and controlled-environment cultivation systems that use warm-water circulation through the same class of pipe.
The most visible end product is the floor heating coil itself, typically 16 or 20 millimeter PE-RT with an EVOH barrier, delivered on reels with a printed label. Manifold branch pipes, riser connections and radiant loop returns are the other common fabricated items that depend on the same consistent barrier quality.
Servicio y soporte de Faygo
A precision barrier line is a long-term asset, and Faygo supports it across its whole life. As a Wanplas factory, Faygo applies the group’s shared service commitments while adding pipe-line-specific expertise.
- Testing before shipment – every line runs a 72-hour continuous operation test at the factory before delivery, so commissioning starts from a proven baseline rather than a cold commissioning gamble.
- Installation and commissioning – engineers supervise on-site installation, alignment, piping and first production, tuning the die head and calibration to the customer’s material.
- Spare parts policy – Faygo provides USD 500 free spare parts every year together with warranty replacement for damaged parts, keeping routine maintenance affordable.
- Training – Los operadores y el personal de mantenimiento se forman en el arranque, la configuración de parámetros, el control de capas, la limpieza del lado de EVOH y la solución de problemas de rutina.
- Remote operation and maintenance – the intelligent control system supports remote monitoring and diagnosis, so process drift can be analyzed without a site visit.
- Fábrica abierta – customers are welcome to visit the Zhangjiagang facilities, review the production process and audit quality before and after purchase.
- Full-plant turnkey consultation – through the Wanplas group, Faygo advises on water and electricity design, factory site layout with 3D workshop planning, worker configuration and training, new factory construction from zero, old machine replacement with zero downtime, and capacity expansion that removes bottlenecks.
This end-to-end support is what lets a first-time pipe producer reach a stable, compliant barrier product without building the know-how from scratch, and it is a core part of the Faygo value proposition for international buyers.
Preguntas frecuentes
What is the difference between five-layer and three-layer oxygen barrier floor heating pipe?
A five-layer pipe stacks PE-RT, tie, EVOH, tie and an outer PE protection layer, giving the most robust barrier and the best protection of the EVOH from mechanical damage during coiling and installation. A three-layer pipe combines the two tie layers into one adhesive composite or places the EVOH with an integral adhesive, reducing equipment cost and complexity while still meeting the oxygen permeability limit. The five-layer structure is preferred where handling abuse and long-term abrasion are concerns.
¿Por qué se deben ajustar las ventanas de temperatura de fusión de PE-RT y EVOH en la coextrusión?
PE-RT processes at roughly 200 to 230 degrees Celsius while EVOH processes at roughly 200 to 220 degrees Celsius. If the two melts meet at the die head with a large temperature gap, viscosity mismatch causes layer instability, thickness drift and weak interlayer adhesion. Matching the melt temperatures keeps both layers in a stable, comparable viscosity range so the EVOH layer stays continuous and centered.
¿Cuán delgada puede ser la capa de barrera de oxígeno y aún cumplir con el límite de DIN 4726?
In practice a controlled EVOH layer of 0.08 to 0.15 millimeter already provides an oxygen permeability well below 0.32 mg per cubic meter per day at 40 degrees Celsius. The engineering challenge is not the absolute minimum thickness but holding the thickness stable within plus or minus 10 percent across the full length and across speed changes, which is why precision co-extrusion control matters more than chasing an ultra-thin layer.
What causes EVOH layer discontinuity and how is it prevented?
Discontinuity usually comes from melt pressure fluctuation in the EVOH extruder, inadequate drying of the EVOH, or a clogged or unbalanced flow channel in the co-extrusion die head. Prevention means stabilizing screw speed and melt pressure, drying EVOH to the required moisture level, balancing the spiral mandrel flow and verifying layer continuity by cross-section microscopy on a regular schedule.
Why does EVOH need drying before co-extrusion and what happens if it is not dried?
EVOH is highly hygroscopic and absorbs moisture from the air. If it enters the barrel with excessive moisture, the water flashes into steam in the melt, creating bubbles, surface splay, weak interlayer bonding and a discontinuous barrier layer. A properly sized dehumidifying dryer brings the moisture down to the required level and keeps it there before the material reaches the co-extrusion die head.
¿Qué configuración de Faygo debo elegir para tuberías de barrera al oxígeno de PE-RT de 16 a 32 milímetros?
Para tuberías de calefacción de suelo de PE-RT de cinco capas de 16 a 32 milímetros y una producción estándar de 60 a 120 kg por hora, la línea de extrusión de tuberías Faygo PP-R/PE-RT en su configuración de barrera contra el oxígeno de cinco capas es la opción típica. Para una mayor producción de 120 a 200 kg por hora en tuberías de 16 a 25 milímetros, la configuración multi-capa de alta producción de la serie de extrusión de tuberías Faygo con tres o cinco capas seleccionables es más adecuada. La selección final depende del diámetro objetivo, la estructura de capas y la producción por hora.
¿Cómo se verifica la permeabilidad al oxígeno para una línea de producción de tuberías de barrera de oxígeno?
Samples are cut from the production run and tested in a permeation cell at 40 degrees Celsius following DIN 4726, and cross-checked against GB/T 28799 and ISO 22391 requirements. A compliant oxygen barrier pipe must show oxygen permeation of 0.32 mg per cubic meter per day or lower. Espesor de la capa and continuity are confirmed by microscope cross-section alongside the permeation result.
¿Qué soporte ofrece Faygo para la instalación, la puesta en marcha y las piezas de repuesto?
Faygo runs a 72-hour continuous operation test before delivery, supplies on-site installation and commissioning, provides USD 500 free spare parts every year with warranty replacement, delivers operator training, supports remote operation and maintenance, welcomes factory visits and offers full-plant turnkey consultation through the Wanplas group.
Conclusión
Equipo de extrusión de precisión de tubería de calefacción geotérmica con barrera al oxígeno para la instalación de tuberías de calefacción geotérmica en interiores. is, at its core, a problem of holding a thin, moisture-sensitive EVOH layer stable inside a fast-moving polyethylene pipe. The technology that solves it combines a barrier-screw main extruder, two to four precisely metered side extruders, a flow-balanced multi-layer co-extrusion die head, a vacuum calibration tank and staged cooling, a synchronized haul-off unit, online measurement and disciplined material drying. Five-layer and three-layer constructions both meet the 0.32 mg per cubic meter per day oxygen limit at 40 degrees Celsius, and the choice between them is an equipment and durability decision rather than a compliance one.
Faygo, a Wanplas factory with 22 years of pipe and profile extrusion experience, three specialized factories, 13 national patents and CE and ISO certified production, builds these lines on the proven Línea de extrusión de tuberías PP-R/PE-RT and Extrusión de tuberías Core Series platforms. Whether a buyer needs 60 kg/h on a compact five-layer line or 200 kg/h on a high-output multi-layer line, the control philosophy is the same: steady melt pressure, matched melt temperatures, balanced die head flow and clean EVOH handling. We invite you to send your target pipe diameter, layer structure and hourly output so our engineering team can propose a tailored configuration, arrange a factory visit, and run a sample trial on the actual line before you commit. Reliable oxygen barrier floor heating pipe starts with the right precision extrusion equipment, and that is what we build.
