Indoor geothermal, more commonly called floor heating, has become the default comfort solution for residential apartments, villas, schools, hospitals and light-commercial buildings across Europe, Central Asia and East Asia. The pipe that carries warm water through the screed is no longer a plain polyethylene tube. Modern specifications demand an oxygen barrier layer that blocks dissolved oxygen from entering the circuit, because oxygen in the water accelerates corrosion of the metal components of the heating system. Oxygen Barrier PE Floor Heating Pipe Precision Extrusion Equipment For Indoor Geothermal Heating Pipeline Installation is therefore a precision multi-layer co-extrusion system, not a simple single-material pipe line. Faygo, pabrik Wanplas 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.
Oxygen Barrier Pipe Structure and Governing Standards
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.
The three-layer (3-layer) structure collapses the stack into PE-RT, a combined adhesive plus EVOH barrier layer, and an outer PE layer. In some designs the EVOH is co-extruded with an integral adhesive so only three physical layers are formed. The three-layer design uses fewer extruders, a simpler co-extrusion die head and a lower equipment cost, while the five-layer design gives the most robust barrier protection and the best defense against handling damage.
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
The decisive performance number is oxygen permeation. For oxygen barrier floor heating pipe the requirement is oxygen permeability of 0.32 mg per cubic meter per day or lower, measured at 40 degrees Celsius, under the DIN 4726 method. This limit exists because oxygen that diffuses through the pipe wall into the water reacts with steel, brass and aluminum components such as manifolds, valves, pumps and radiators, accelerating corrosion and shortening system life.
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
Material selection decides the processing window, the line speed and the final cost. Three polymer families matter: PE-RT as the structural base, PEX as the main alternative crosslinked base, and EVOH as the barrier. Each behaves differently in the barrel and at the die head.
PE-RT Type I and Type II properties
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.
PEX crosslinking alternatives (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.
Masalah praktis utama dengan EVOH adalah kelembaban. EVOH sangat higroskopis dan menyerap air dari udara, dan air tersebut harus dihilangkan sebelum bahan tersebut masuk ke tabung. EVOH yang tidak kering meledak menjadi uap di cairan dan menghasilkan gelembung, penyebaran permukaan, ikatan antar lapisan yang lemah, dan lapisan barier yang tidak kontinu. Pemanas dehumidifier yang disesuaikan dengan throughput EVOH menjadi bagian wajib dari jalur, bukan aksesori opsional. Kebutuhan pengeringan adalah salah satu perbedaan mendasar antara jalur pipa barier dan jalur pipa komoditas.
Anatomy of a Precision Multi-Layer Co-Extrusion Line
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. Die head temperature profiling, independent side-extruder barrel control and careful selection of EVOH grade are the tools that achieve this match.
Faygo Line Konfigurasis and Specification 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 Line Ekstrusi Pipa PP-R/PE-RT and the Seri Pipa Extrusi Faygo Ekstrusi pipa Core Series, both of which are real Wanplas-group product lines used for pipe diameters from 12 to 575 millimeters with wall thickness up to 6.5 millimeters. The tables list the parameters a buyer actually evaluates.
Faygo Line Ekstrusi Pipa PP-R/PE-RT, five-layer oxygen barrier configuration
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.
| Paramater | Faygo Specification |
|---|---|
| Applicable pipe diameter | 16 to 32 mm (PE-RT floor heating pipe) |
| 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) |
| Co-extrusion layers | 5 (PE-RT / tie / EVOH / tie / PE outer) |
| Output | 60 to 120 kg/h |
| Line speed | 8 to 25 m/min |
| Tenaga yang terpasang | 145 kW |
| Kalibrasi dan pendinginan section length | vacuum calibration tank 6 m + spray cooling tank 12 m |
| Haul-off type | 2-caterpillar belt haul-off unit |
Seri Pipa Extrusi Faygo Ekstrusi pipa Core Series, konfigurasi multi-layer dengan output tinggi
For producers targeting higher hourly output on 16 to 25 millimeter pipe, the Seri Pipa Extrusi Faygo Ekstrusi pipa Core Series 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.
| Paramater | Faygo Specification |
|---|---|
| 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 (adhesive composite) + 1 x 30 mm (outer) |
| Co-extrusion layers | 3 or 5 selectable |
| Output | 120 to 200 kg/h |
| Line speed | 12 to 40 m/min |
| Tenaga yang terpasang | 185 kW |
| Kalibrasi dan pendinginan section length | 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.
Kontrol Kepala Die dan Ketebalan Lapisan
The die head is where the barrier layer is born, and layer thickness control is where most quality problems are won or lost. The objective is a thin, continuous, centered EVOH layer whose thickness stays within a tight band for the entire length of the coil.
Controlling EVOH layer thickness and deviation
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.
Adhesi antar lapisan dan kekuatan pelepasan
The tie layers exist to bond polyethylene to EVOH, and their thickness and placement determine the interlayer peel strength. Too little tie resin and the barrier delaminates during coiling or on the building site; too much adds cost without benefit. Peel strength is verified by a layered peel test on a cross-section sample, and it is sensitive to the melt temperature match described earlier: when PE-RT and EVOH meet at the correct, close temperatures, the tie layer wets both surfaces and bonds well. The die head must also keep the melt pressures of adjacent layers close so one layer does not overpower and thin the next.
Kalibrasi Vakum dan Pendinginan
Setelah campuran melamin keluar dari kepala die, ia harus dibekukan menjadi diameter luar dan bentuk bulat yang tepat sebelum dapat bergerak. Ini adalah tugas bagian kalibrasi dan pendinginan, dan di sini bentuk oval dan kualitas permukaan ditetapkan.
Calibration sleeve and vacuum level
The pipe is pulled over a calibration sleeve, a precision-bored tube that sets the outside diameter. The sleeve material is typically brass or stainless steel, with stainless steel preferred for wear resistance and clean surface. A vacuum is drawn through slots in the sleeve to pull the soft melt firmly against the bore. The practical vacuum range is -0.02 to -0.06 MPa. Too little vacuum and the pipe does not seat; too much and the wall is sucked thin or the surface marks. The vacuum calibration tank holds the sleeve and the first, most aggressive cooling water.
Gradien suhu air dan bentuk oval
Pendinginan diatur dalam bentuk gradien suhu, bukan dalam satu kolam dingin. Bagian pertama berjalan pada suhu 12 hingga 18 derajat Celsius untuk mengatur bentuk dengan cepat tanpa tekanan termal yang akan menahan stres, dan bagian-bagian selanjutnya berjalan secara bertahap lebih hangat untuk pendinginan yang lembut. Panjang kolam harus sesuai dengan kecepatan garis: pada kecepatan tinggi, pipa membutuhkan lebih banyak panjang kolam untuk mencapai suhu akhir yang sama, atau ia keluar lunak dan oval. Bentuk oval, deviasi dari bentuk lingkaran yang sebenarnya, dikendalikan oleh vakuum yang stabil, suhu air yang seimbang, dan tabung kalibrasi yang dalam kondisi baik. Pipa yang keluar dari kolam oval akan tetap oval dan mungkin gagal memenuhi persyaratan dimensi di lokasi konstruksi.
Pengangkutan, Pengukuran, dan Pembungkusan
Ujung bawah garis mengukur, memotong, atau membungkus dan memasang pipa yang sudah selesai. Keakuratan di sini melindungi investasi yang telah dilakukan di bagian atas.
Sinkronisasi dan pengukuran online
Unit pengangkut menarik pipa dengan kecepatan garis yang ditetapkan oleh keluaran ekstruder. Unit pengangkut serangga menggunakan pita atau bantalan yang menahan pipa tanpa merusaknya, dan sinkronisasi kecepatannya dengan ekstruder dan pemotong adalah yang mencegah perubahan ketebalan dan kerusakan permukaan sambungan bambu. Pengukuran diameter laser secara online memberikan diameter luar dalam waktu nyata, dan target toleransi adalah plus atau minus 0,1 hingga 0,3 milimeter tergantung pada diameter. Pengukuran ketebalan dinding ultrasonik memeriksa dinding di sepanjang lingkar tanpa memotong pipa, menangkap eksentrisitas secara dini. Kontrol meter mencatat panjang untuk pemasangan gulungan atau label paket.
Pengukuran dan pengikatan otomatis
Floor heating pipe is usually delivered as coils rather than straight lengths, so an automatic coiler winds the pipe to a set length and then the cutting unit severs it cleanly. The coiler must wind without kinking or over-tensioning, because a kink becomes a weak point in the floor. Packaging follows, often with a printed label carrying the material, diameter, length and standard marks. The whole downstream sequence is tied into the central control system so a speed change at the extruder propagates instantly to the haul-off, cutter and coiler.
Parameter Proses Referensi untuk Ukuran Pipa Umum
Tabel di bawah ini memberikan parameter proses referensi untuk ukuran pipa pemanas lantai dengan lapisan pelindung oksigen yang paling umum. Ini adalah titik awal; setiap garis diatur untuk sekrup, kepala die, dan lot bahan masing-masing. Suhu adalah pengaturan zona tabung yang memberi makan ke kepala die, nilai vakum dan air adalah target kalibrasi dan pendinginan pertama, dan keluaran dan kecepatan garis adalah titik operasi yang dihasilkan.
| Pipe size (mm) | Output (kg/h) | Kecepatan jalur (m / menit) | 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 |
Extruder EVOH dan sisi sambungan beroperasi dengan throughput yang lebih rendah masing-masing, yang disetel untuk menghasilkan ketebalan lapisan yang diinginkan pada kecepatan jalur yang dipilih. Operator mengoptimalkan seluruh set bersama-sama, karena mengubah kecepatan jalur tanpa merebalaskan extruder sisi adalah cara tercepat untuk mendapatkan lapisan barier yang tidak memenuhi persyaratan.
Quality Inspection Items
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 | Condition | Acceptance |
|---|---|---|
| Hydrostatic test | 95 deg C / 1000 h | No failure, no leakage |
| Oxygen permeability | 40 deg C, DIN 4726 | 0.32 mg/(m3·d) or lower |
| Layer thickness | Microscopy cross-section | EVOH 0.08 to 0.15 mm, deviation within plus or minus 10 percent |
| Peel strength | Interlayer | No delamination |
| Longitudinal reversion | Per standard | 3 percent or lower |
| Melt flow rate | 190 deg C / 2.16 kg | 0.5 to 1.0 g/10min |
| Carbon black dispersion | If applicable | Even, no agglomeration |
| Appearance and ovality | 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.
| Defect | 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 |
| Ovality out of tolerance | Unstable vacuum, uneven cooling | Adjust vacuum, balance water temperature gradient |
| Wall eccentricity | Die centering offset | Adjust die lip bolts, center the mandrel |
| Inner wall pitting | Moisture or gas, dirt in melt | Dry materials, clean die head, dehumidify EVOH |
| Color difference | Masterbatch or regrind variance | Standardize color masterbatch, control regrind ratio |
| Bubbles in barrier layer | EVOH not dried | Dry EVOH to required moisture, preheat hopper |
Kebanyakan kerusakan ini dapat ditelusuri kembali ke dua penyebab utama: tekanan cairan yang tidak stabil dan kelembaban dalam EVOH. Jalur yang mengendalikan kedua variabel tersebut dengan ketat, pada praktiknya, akan menghindari kebanyakan kegagalan yang khusus untuk barier.
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.
Selection Guide: Matching Requirement to Faygo Konfigurasi
Tabel di bawah ini mengubah persyaratan pembeli menjadi konfigurasi Faygo yang disarankan. Ini adalah titik awal untuk penawaran yang rinci; pemilihan akhir juga tergantung pada kondisi utilitas lokal, ruang lantai yang tersedia, dan standar pasar target.
| Pipe diameter | Layer structure | Target output | Recommended Faygo configuration |
|---|---|---|---|
| 16 to 20 mm | 5-layer | 60 to 120 kg/h | Faygo Line Ekstrusi Pipa PP-R/PE-RT, five-layer oxygen barrier configuration |
| 16 to 25 mm | 3 or 5-layer | 120 to 200 kg/h | Seri Pipa Extrusi Faygo Ekstrusi pipa Core Series, konfigurasi multi-layer dengan output tinggi |
| 20 to 32 mm | 5-layer, thicker wall | 80 to 150 kg/h | Faygo Line Ekstrusi Pipa PP-R/PE-RT with enlarged calibration and cooling |
| Trial or R and D small batch | 3 or 5-layer | Low | Seri Pipa Extrusi Faygo Ekstrusi pipa Core Series 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.
Aplikasi Across Industries
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 – Pasar utama: gulungan yang diletakkan di screed untuk apartemen, vila, sekolah, rumah sakit, dan kantor, menyediakan panas radiasi rendah yang merata dan nyaman.
- 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 – pipa jaringan sekunder yang dipre-insulasi di mana barier mengurangi korosi komponen baja di stasiun energi dan ruang manajemen.
- Agricultural irrigation – loop pemanas rumah kaca dan perkebunan dan sistem budidaya lingkungan yang dikontrol yang menggunakan sirkulasi air hangat melalui jenis pipa yang sama.
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.
Layanan dan Dukungan from Faygo
Jalur barier yang presisi adalah aset jangka panjang, dan Faygo mendukungnya sepanjang hidupnya. Sebagai pabrik Wanplas, Faygo menerapkan komitmen layanan bersama grup sementara menambahkan keahlian khusus untuk pipa.
- Pengujian sebelum pengiriman – every line runs a Uji operasi terus-menerus selama 72 jam 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 – operators and maintenance staff are trained on start-up, parameter setting, layer control, cleaning the EVOH side and routine troubleshooting.
- Remote operation and maintenance – sistem kontrol cerdas mendukung pemantauan dan diagnosis jarak jauh, sehingga gangguan proses dapat dianalisis tanpa kunjungan ke tempat.
- Open factory – pelanggan diundang untuk mengunjungi fasilitas Zhangjiagang, memeriksa proses produksi dan mengaudit kualitas sebelum dan setelah pembelian.
- Full-plant turnkey consultation – melalui grup Wanplas, Faygo memberikan saran tentang desain listrik dan air, tata letak pabrik dengan perencanaan workshop 3D, konfigurasi pekerja dan pelatihan, konstruksi pabrik baru dari nol, penggantian mesin lama dengan waktu tidak berhenti, dan ekspansi kapasitas yang menghilangkan hambatan.
Dukungan end-to-end ini memungkinkan produsen pipa pertama kali mencapai produk barier yang stabil dan memenuhi persyaratan tanpa membangun pengetahuan dari awal, dan merupakan bagian inti dari nilai jual Faygo untuk pembeli internasional.
Pertanyaan yang Sering Diajukan
What is the difference between five-layer and three-layer oxygen barrier floor heating pipe?
Pipa lima lapis menumpuk PE-RT, ikatan, EVOH, ikatan, dan lapisan pelindung PE luar, memberikan barier yang paling kuat dan perlindungan terbaik EVOH dari kerusakan mekanis selama penggalian dan pemasangan. Pipa tiga lapis menggabungkan dua lapisan ikatan menjadi satu komposit perekat atau menempatkan EVOH dengan perekat integral, mengurangi biaya peralatan dan kompleksitasnya, sementara masih memenuhi batas permeabilitas oksigen. Struktur lima lapis lebih disukai di mana penanganan yang tidak tepat dan abrasi jangka panjang menjadi perhatian.
Why must the melt temperature windows of PE-RT and EVOH be matched in co-extrusion?
PE-RT diproses pada suhu sekitar 200 hingga 230 derajat Celsius, sedangkan EVOH diproses pada suhu sekitar 200 hingga 220 derajat Celsius. Jika kedua cairan bertemu di kepala die dengan kesenjangan suhu yang besar, ketidaksesuaian viskositas menyebabkan tidak stabilitas lapisan, perubahan ketebalan, dan keterikatan antar lapisan yang lemah. Menyesuaikan suhu cairan menjaga kedua lapisan dalam rentang viskositas yang stabil dan dapat dibandingkan sehingga lapisan EVOH tetap kontinu dan terpusat.
How thin can the EVOH oxygen barrier layer be and still meet the DIN 4726 limit?
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.
Apa yang menyebabkan ketidak-kontinuitas lapisan EVOH dan bagaimana mencegahnya?
Ketidak-kontinuitas biasanya berasal dari fluktuasi tekanan cairan di extruder EVOH, pengeringan EVOH yang tidak memadai, atau saluran aliran yang tersumbat atau tidak seimbang di kepala die ekstrusi. Pencegahan berarti menstabilkan kecepatan putar dan tekanan cairan, mengeringkan EVOH ke tingkat kelembaban yang diinginkan, menyesuaikan aliran saluran spiral, dan memverifikasi kontinuitas lapisan dengan mikroskop cross-section pada jadwal yang teratur.
Why does EVOH need drying before co-extrusion and what happens if it is not dried?
EVOH sangat higroskopis dan menyerap kelembaban dari udara. Jika masuk ke tabung dengan kelembaban yang berlebihan, air meledak menjadi uap di cairan, menciptakan gelembung, penyebaran permukaan, ikatan antar lapisan yang lemah, dan lapisan barier yang tidak kontinu. Pemanas dehumidifier yang disesuaikan dengan throughput EVOH menurunkan kelembaban ke tingkat yang diinginkan dan menjaganya tetap di sana sebelum bahan tersebut mencapai kepala die ekstrusi.
Apa konfigurasi Faygo yang harus saya pilih untuk pipa PE-RT yang tahan oksigen dengan diameter 16 hingga 32 milimeter?
For standard 16 to 32 millimeter five-layer PE-RT floor heating pipe at 60 to 120 kg per hour, the Faygo Line Ekstrusi Pipa PP-R/PE-RT in its five-layer oxygen barrier configuration is the typical choice. For higher output of 120 to 200 kg per hour on 16 to 25 millimeter pipe, the Seri Pipa Extrusi Faygo Ekstrusi pipa Core Series high-output multi-layer configuration with selectable three or five layers is more suitable. Final selection depends on target diameter, layer structure and hourly output.
Bagaimana permeabilitas oksigen diukur untuk jalur produksi pipa barier oksigen?
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. Layer thickness and continuity are confirmed by microscope cross-section alongside the permeation result.
Apa dukungan yang diberikan Faygo untuk instalasi, pengaturan, dan suku cadang?
Faygo menjalankan uji operasi terus-menerus selama 72 jam sebelum pengiriman, menyediakan instalasi dan pengaturan di tempat, menyediakan suku cadang gratis sebesar USD 500 setiap tahun dengan penggantian garansi, menyediakan pelatihan operator, mendukung operasi dan pemeliharaan jarak jauh, menyambut kunjungan ke pabrik, dan menawarkan konsultasi turnkey pabrik penuh melalui grup Wanplas.
Kesimpulan
Oxygen Barrier PE Floor Heating Pipe Precision Extrusion Equipment For Indoor Geothermal Heating Pipeline Installation 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, pabrik Wanplas 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 Line Ekstrusi Pipa PP-R/PE-RT and Ekstrusi pipa 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.
