目次
- 1. What Is a Silicone Core パイプ押出ライン and Why Buried Optical Cable Protection Needs It
- 2. Product family, specification system and application background
- 3. Material system: HDPE base resin and silicone masterbatch
- 4. Complete production line configuration and equipment parameters
- 5. Faygo パイプ押出ライン for silicone core communication duct
- 6. Faygo telecom conduit portfolio and co-extrusion readiness
- 7. Key technical challenges of high speed extrusion
- 8. Process parameter reference
- 9. Quality standards and in-line testing
- 10. Demand to line configuration recommendation
- 11. Line economics, energy and maintenance
- 12. Common defects and troubleshooting
- 13. Faygo services, testing and support
- 14. Frequently asked questions
- 15. Conclusion and how to start your project
What Is a Silicone Core パイプ押出ライン and Why Buried Optical Cable Protection Needs It
A silicone core パイプ押出ライン is a specialized high speed plastic pipe production line that manufactures HDPE communication conduit with a permanently co-extruded inner layer of solid silicone lubricant. In the field, this product is most often called silicone core duct, HDPE silicon core pipe, or silicon core pipe. The defining feature is that, during the same extrusion pass that forms the HDPE wall, a thin layer of ultra-high-molecular-weight siloxane is co-extruded onto the inner surface and then bonds into a smooth, durable, low-friction film. That internal film is what makes the pipe different from an ordinary smooth-wall HDPE duct. The practical reason this pipe exists is air-blown cable installation, also called air-blowing or jetting. In buried optical cable networks, installers do not pull the cable through the duct with a winch the way they would with a traditional conduit. Instead, they insert the cable at one access point, connect a compressor, and use a controlled stream of compressed air to blow the lightweight optical cable along the inside of the duct. A standard smooth HDPE inner wall has a friction coefficient in the range of 0.30 to 0.45, which means the cable drags and the blowable distance is short, often only a few hundred meters before air pressure can no longer overcome friction. A silicone core duct reduces that friction coefficient to roughly 0.05 to 0.12. With that low internal friction, a single air-blowing operation can place a communication cable continuously for 1000 to 2000 meters, sometimes more, depending on duct diameter, cable mass, and the compressor capacity on site. For long-haul backbone routes, metropolitan area networks, highway and railway communication corridors, and power utility communication, that reach is decisive. It cuts the number of splice chambers and manholes, reduces civil works, and lets operators light up a route faster. The pipe must therefore survive direct burial for decades, resist ultraviolet light before backfilling, tolerate soil loading, and keep its internal lubricant layer intact so the cable can be blown in years after the pipe was installed. 製造 that product at commercial speed is a discipline in itself, and it is the discipline this guide addresses. Faygo, a Wanplas factory, is a specialist in plastic pipe and profile extrusion lines with 22 years of dedicated experience, operating three specialized factories and holding 13 national patents including 8 invention patents. The pipe extrusion know-how that Faygo applies to water, gas, drainage, and agricultural irrigation lines transfers directly to communication cable protection duct, and the same intelligent control architecture, the same CE and ISO certified build standard, and the same 72-hour pre-delivery running test that Faygo applies to its pipe lines are exactly what a silicone core duct producer needs.Product Family, 仕様書 System and Application Background
Definition and working principle of silicone core duct
シリコーンコアダクトは、内壁に永続的な固体シリコーン潤滑層を形成するHDPEパイプです。シリコーンはパイプがダイから出た後に塗布されるコーティングではなく、複数層のダイヘッドに個別の溶融流として導入され、両方の材料がまだ溶融している間にダイの境界面で融着されます。冷却後、シリコーンは繰り返しケーブルを吹き込むときに剥がれにくい、低摩擦の安定した膜を形成し、保管されたコイル内で自らに再び付着しません。測定可能な利点は、ケーブルジャケットに対する運動摩擦係数が0.05から0.12であり、未修飾HDPE内壁の場合は0.30から0.45です。仕様書 system
The communication duct market is dominated by a handful of outside diameters. The table below collects the most common commercial sizes, their wall thickness bands, the corresponding standard dimension ratio, and the typical coil length used in direct buried installation.| Outside 直径(mm) | Typical Wall (mm) | SDR | Common OD/ID Marking | Coil Length (m) |
|---|---|---|---|---|
| 32 | 3.0 – 4.0 | 11 / 13.6 | 32/26, 32/28 | 1000 – 2000 |
| 40 | 3.0 – 4.5 | 11 / 13.6 | 40/33, 40/34 | 1000 – 2000 |
| 46 | 3.5 – 4.5 | 11 / 13.6 | 46/38 | 1000 – 2000 |
| 50 | 4.0 – 4.5 | 11 / 13.6 | 50/41 | 1000 – 2000 |
Structural variants
- Single-hole silicone core pipe. The baseline product: one HDPE tube with a co-extruded silicone inner layer. Used for direct buried backbone and access routes.
- Multi-hole bundled duct. Several silicone core tubes are grouped into one outer jacket, typically in 3-hole, 4-hole, or 7-hole configurations. This lets a single trench carry multiple independent cable routes and is common in dense metropolitan deployments.
- Ribbed inner wall duct. The inner surface carries longitudinal ribs in addition to the silicone layer. The ribs reduce the contact area between cable and wall, further lowering effective friction and improving air-blow distance.
- Color-striped duct. Four longitudinal color stripes are co-extruded into the wall for route identification without opening the coil. Combined with silicone core, this is the standard identification scheme for multi-route networks.
How air-blowing actually loads the pipe
Understanding why the extrusion line must be so precise starts with understanding the physics of the installation method the pipe was designed for. In air-blown installation, compressed air moving along the annular gap between cable and duct wall exerts a distributed viscous drag on the cable jacket, pushing it forward along the entire length that is already inside the duct rather than pulling it from one end. This distributed force is what makes long single-pass runs possible. But the same physics means the cable rests on the bottom of the duct under its own weight, and every meter of contact generates friction that consumes part of the available driving force.
Three properties of the pipe therefore determine the achievable blowing distance. The first is the friction coefficient of the inner surface, which the silicone layer addresses directly. The second is the consistency of the inner diameter, because a local constriction acts as a brake and a local enlargement leaks air pressure. The third is the straightness and ovality of the pipe after coiling and laying, because ovality reduces the effective annular gap and increases the contact arc between cable and wall. A pipe that measures perfectly in a short laboratory sample but drifts in diameter over 1000 meters will underperform in the field. That is why in-line laser diameter measurement and closed-loop wall control are not optional refinements on a communication duct line; they are the difference between a duct that blows to specification and one that stalls at 600 meters and forces the contractor to open an unplanned access pit.
The same reasoning explains the value of the ribbed inner wall variant. By raising a series of longitudinal ribs, the design converts a continuous line contact between cable and wall into a series of narrow contact points. Less contact area means less friction work per meter, and the grooves between ribs also give the air a lower-resistance path along the duct. For very long runs or heavier cables, this structural change can add meaningful distance on top of what the silicone chemistry delivers. Producing it, however, demands a die mandrel with rib geometry that stays dimensionally stable at high throughput and a calibration system that does not iron the ribs flat, which is a genuine test of die and sizing engineering.
Application background
Silicone core duct serves the communication infrastructure that underpins modern connectivity. The principal applications are:
- Long-distance optical cable backbone routes between cities and regions.
- Metropolitan area networks and fiber-to-the-home distribution trunks.
- Communication corridors along expressways and railways, where trenching is expensive and route access is limited.
- Power utility communication, where the duct shares corridors with electrical infrastructure.
- 5G fronthaul and backhaul pipe networks, where dense small-cell rollout multiplies the number of cable routes.
Because the cable is installed by air-blowing rather than pulling, the pipe is the real enabling asset of the network. A pipe that loses its lubricity, develops eccentricity, or suffers wall delamination will raise installation cost for the entire project life. The extrusion line is therefore the foundation of the whole business case.
材料システム: HDPE Base Resin and Silicone Masterbatch
Getting the material right is the first half of making a good silicone core duct. The base pipe is high-density polyethylene, and the inner layer is a siloxane-rich compound. The two must co-extrude cleanly, fuse at the interface, and cool into a dimensionally stable product.
HDPE pipe grade
For buried communication duct, the base resin is a PE80 or PE100 grade high-density polyethylene. The key specification points are melt flow rate, density, environmental stress crack resistance, and carbon black content for ultraviolet protection.
| Material Parameter | HDPE Base Pipe Resin | Silicone Masterbatch (Inner Layer) |
|---|---|---|
| Grade | PE80 / PE100 | UHMW siloxane masterbatch |
| MFR (190 deg C / 5 kg) | 0.2 – 0.8 g/10 min | carrier resin MFR matched to base |
| Density | 0.945 – 0.960 g/cm3 | depends on carrier |
| ESCR (ASTM D1693) | > 2000 h | n/a |
| カーボンブラック含有量 | 2.0 – 2.5 percent | optional for ID layer |
| Addition ratio in inner layer | base | 20 – 50 percent |
| Inner layer thickness | wall 3.0 – 4.5 mm total | 0.15 – 0.35 mm |
カーボンブラックの負荷率は2.0から2.5％ですが、この値は形容的ではなく真剣です。埋設されたダクトまたは開放型の保管用でカーボンブラックは主な紫外線安定剤であり、この物質が使用されていないと日光暴露下でパイプが傷つきます。ASTM D1693で定められた耐環境応力割れ抵抗度の2000時間以上を満たすことは、土壌や岩石との接触部において微小な割れがゆっくりと拡大するのを防止します。
シリコーンマスターバッチ
The inner lubricant layer is built from an ultra-high-molecular-weight siloxane masterbatch. This is added at 20 to 50 percent into the inner-layer compound, and the finished inner film is 0.15 to 0.35 mm thick. The engineering challenge is migration control: the siloxane must bloom to the surface enough to form a stable lubricating film, but it must not migrate so aggressively that the layer delaminates or that the silicone bleeds onto the outer wall. A well-designed compound and a clean co-extrusion interface give a bonded layer that survives coiling, storage, and repeated cable blowing.
カラーストライプコンパウンド
The four identification stripes are made from HDPE plus a color masterbatch, distributed symmetrically around the circumference. The stripe extruders are small and independent, and the stripe position is locked by die geometry rather than by operator adjustment.
Material pre-treatment
HDPE is generally non-hygroscopic and does not require drying for normal production. However, in the rainy season or when the formulation contains regrind, a dehumidifying dryer run for about 3 hours at 80 degrees C removes surface moisture that would otherwise appear as bubbles in the wall. シリコーンマスターバッチ must be kept dry because siloxane carrier resins are sensitive to moisture pickup, which shows up as splay and poor layer uniformity.
生産ラインの構成と装置パラメータ
A silicone core duct line is a multi-layer co-extrusion system. Beyond the conventional single-screw extrusion lines used for plain HDPE pipe, it adds a dedicated inner-layer extruder for the silicone compound and usually two to four micro-extruders for the color stripes. The table below is the core equipment list with the parameter bands that define a commercial high speed line.
| Line Section | Equipment | Key Parameters |
|---|---|---|
| Main extruder | Single-screw | Screw diameter 65 – 90 mm, L/D 33 – 38:1, barrier screw + mixing head, output 250 – 600 kg/h, installed power 90 – 200 kW, 5 – 7 barrel zones |
| Inner layer extruder | シングルスクリュー共押出機 | Screw diameter 30 – 45 mm, L/D 25 – 30:1, output 10 – 40 kg/h |
| Color stripe extruders | 2 – 4 micro extruders | Screw diameter 20 – 25 mm |
| Die head | 3層共押出しスパイラルマンドレル | Hard chrome flow path, adjustable die and mandrel eccentricity, head pressure 15 – 30 MPa |
| Vacuum calibration | Vacuum calibration tank | 校正スリーブ brass or stainless, vacuum -0.02 to -0.06 MPa, spray cooling 12 – 20 deg C, tank length 6 m |
| Cooling | Cooling water tanks | 2 – 3 sections x 6 m, water gradient 20 to 15 to 12 deg C |
| Haul-off | Caterpillar haul-off | 6 – 12 tracks, line speed 40 – 80 m/min high speed, speed sync precision +/-0.5 percent |
| On-line inspection | Measurement and marking | レーザー直径ゲージ +/-0.1 mm, ultrasonic wall thickness, meter counter, inkjet printer |
| Winding | Dual-station automatic winder | Coil length 1000 – 2000 m, automatic laying and non-stop changeover |
| Auxiliary | Support systems | Central feeding, vacuum loader, regrind closed loop, water chiller |
The main extruder carries a barrier screw with a mixing section, often a Maddock or pineapple-style mixing head, because the HDPE melt must be homogenized at high shear without thermal degradation. The inner-layer extruder is small but its metering stability governs silicone layer uniformity, which is why many lines pair it with a gear pump or a precision gravimetric feeder for closed-loop control.
ダイヘッドは、3層共押出しのためのスパイラルマンドレルデザインです。スパイラルマンドレルは、溶融物を周囲に均等に分散させるため、円形パイプと均一な壁面に不可欠です。流路は硬質クロムメッキで覆われており、シロナ硫酸の摩耗に対する耐性を高め、表面粗さを低く保ちます。ダイとマンドレルは、エクセンシシティを修正するために停止せずに調整できます。
Vacuum calibration sets the outside diameter. A calibration sleeve, normally brass or stainless steel, pulls the just-extruded melt onto size while a vacuum of -0.02 to -0.06 MPa holds it against the sleeve and spray water at 12 to 20 degrees C begins the freeze. From there the pipe passes through two or three cooling tanks, each 6 meters long, with a descending water temperature gradient so the pipe cools gradually and resists internal stress that would cause ovality or post-extrusion shrinkage.
The haul-off is a caterpillar type with 6 to 12 belts. On a high speed silicone core line it must hold 40 to 80 meters per minute with speed synchronization precision of plus or minus 0.5 percent, because any slip or speed drift changes wall thickness and breaks the diameter feedback loop.
At the end, a dual-station automatic winder coils 1000 to 2000 meters without stopping the line, laying the pipe evenly so the coil does not deform, and switches to the empty reel automatically.
Screw design for high output HDPE with a co-extruded skin
The screw is where output and melt quality are decided, and on a silicone core duct line it has to satisfy two demands that pull in opposite directions. It must deliver 250 to 600 kg/h of homogeneous melt at stable pressure, and it must do so without generating so much shear heat that the polymer degrades or the melt arrives at the die too hot to cool within the available tank length. A barrier screw solves the first half of the problem. By separating the solid bed from the melt pool with a barrier flight, it forces unmelted pellets to remain in the solids channel until they have melted, which eliminates the unmelted cores and pressure surges that plague conventional metering screws at high output.
The mixing head at the end of the screw solves the second half. A Maddock or pineapple-type mixer distributes any remaining thermal and compositional non-uniformity so the melt entering the die head is consistent from center to wall. This matters more than usual on this product because the carbon black loading of 2.0 to 2.5 percent must be evenly dispersed. Poorly dispersed carbon black shows up in the finished pipe as streaks, and more seriously as local weak points where ultraviolet protection is inadequate. カーボンブラック分散剤 is a formal acceptance test on communication duct, and the screw is the main tool for passing it.
The L/D ratio of 33 to 38:1 gives the residence time needed for both melting and mixing at high throughput. Shorter screws can be pushed to similar outputs, but they do it by raising shear rate, which raises melt temperature, which then loads the cooling section that is already the bottleneck at high line speed. Spending length on the screw buys back cooling capacity downstream, and on a line targeting 60 to 80 meters per minute that trade is almost always worth making.
Die head design and the co-extrusion interface
The three-layer spiral mandrel die is the component that makes this a silicone core line rather than an ordinary pipe line. In a spiral mandrel design, each melt stream is fed into a set of helical channels machined into a mandrel; the channels gradually reduce in depth while the leakage gap over the flight lands increases, so material progressively bleeds from the spirals into an annular gap. By the time the melt reaches the die land, feed-point weld lines have been distributed and overlapped many times, producing a circumferentially uniform flow. For a pipe that will be measured for wall thickness at every angular position, this uniformity is the whole game.
Stacking three of these distributors, one for the outer HDPE wall, one for the silicone-rich inner layer, and one arrangement for the color stripes, requires careful management of the layer junction. The two main melt streams should meet at a point where both are fully distributed and at compatible viscosities, so the interface is smooth rather than wavy. If the inner layer is significantly cooler or more viscous than the base, interfacial instability appears as a rippled or cloudy inner surface. If it is too hot, the thin layer can be dragged and thinned unevenly by the faster-moving base melt. Practically, the inner-layer melt is held slightly below the base at 170 to 200 degrees C against 180 to 220 degrees C, and the exact offset is tuned during commissioning against the specific masterbatch.
Hard chrome plating on the flow path serves two purposes. It resists the abrasive and adhesive wear that siloxane compounds can cause over long production campaigns, and it holds the polished surface finish that suppresses melt fracture. A die that starts at Ra 0.2 micrometers and degrades to a rough surface after a few months will start producing sharkskin at speeds it previously handled cleanly, and the operator will wrongly conclude the line has lost capacity.
Producing multi-hole bundled duct
Bundled duct in 3-hole, 4-hole, or 7-hole formats is a different manufacturing problem, not simply several pipes made at once. Each individual tube must still receive its silicone inner layer and hold its own diameter tolerance, and then the group must be held in a fixed geometric arrangement while an outer jacket is applied or while the tubes are bonded along contact lines. The die becomes a multi-cavity assembly, the calibration section must size several tubes simultaneously and keep them in register, and the haul-off must pull the assembled bundle without twisting it. Twist is the characteristic defect of bundled duct: a bundle that rotates along its length makes it impossible for the installer to identify which tube is which at the far end, which defeats the purpose of a color-coded multi-route duct. Controlling twist comes down to symmetric melt distribution, symmetric cooling, and a haul-off with genuinely parallel tracks.
Faygo パイプ押出ライン for Silicone Core Communication Duct
When the technical discussion reaches the question of which machine to build the duct on, Faygo’s pipe extrusion series is the natural fit. Faygo is a Wanplas factory with 22 years of dedicated experience in plastic pipe and profile extrusion lines, and its pipe extrusion capability covers diameters from 12 to 575 mm in PE, PVC, and PP with wall thickness up to 6.5 mm, including communication cable protection applications.
| パラメータ | Faygo パイプ押出 Series（シリコンコアダクト対応） |
|---|---|
| Applicable pipe diameter | 12 – 575 mm |
| 加工可能な材料 | PE / PVC / PP |
| 最大壁厚 | 6.5 mm |
| Application coverage | Water supply, drainage, gas, communication cable protection, agricultural irrigation |
| コントロールシステム | インテリジェント制御システム, free parameter setting and real-time adjustment |
| Electrical components | Internationally renowned brand electrical components |
| Pre-delivery test | 72-hour continuous operation testing before delivery |
| Certification | CE and ISO certified |
| Patents | 13 national patents including 8 invention patents |
| Factory scale | Three specialized factories, FAYGOPLAST site 26,650 sqm in Zhangjiagang, 2 hours from Shanghai Airport |
For a silicone core communication duct project, Faygo configures the base pipe extrusion section to the 32 to 50 mm duct range, adds the inner-layer co-extruder and stripe extruders, and integrates the spiral mandrel die head, vacuum calibration, multi-stage cooling, high speed caterpillar haul-off, on-line measurement, and dual-station winding into one intelligent control platform. Because the line is built on Faygo’s established pipe extrusion architecture, the same 72-hour continuous running test, the same CE and ISO certified build, and the same intelligent control system that Faygo applies across its pipe lines carry over directly to the silicone core application.
Faygo Telecom Conduit Portfolio and Co-Extrusion Readiness
Beyond the general pipe extrusion series, Faygo offers specific product lines whose diameter ranges and material handling map onto telecom conduit requirements. The table below lists the real Faygo lines that a communication duct producer can draw on, together with their published diameter ranges.
| Faygo ライン | 直径範囲 | Relevance to Communication Duct |
|---|---|---|
| PE/PP/PVC単層波形パイプ押出ライン | 6 – 200 mm | Flexible corrugated communication conduit and protective sheathing |
| PP-R/PE-RTパイプ押出ライン | 16 – 160 mm (PE-RT 16 – 32 mm) | PE-based small to medium conduit and duct bodies |
| PVCパイプ生産ライン | Large diameter, varied wall | PVC cable protection pipe for communication and power |
| パイプ押出 Series (core) | 12 – 575 mm | HDPE silicone core duct base extrusion |
The point for a buyer is integration. Wanplas, as the parent brand, supplies matched upstream and auxiliary capability so a Faygo silicone core line can be delivered as a complete, coordinated package rather than a collection of separately sourced machines. For producers who also run corrugated or PVC communication conduit, the same Faygo engineering team and the same service policy apply across the portfolio, which simplifies spare parts, training, and plant layout.
Key Technical Challenges of High Speed Extrusion
Moving a silicone core line from the 8 to 20 meters per minute typical of conventional HDPE pipe to the 40 to 80 meters per minute of a high speed duct line is not a simple speed dial increase. Every subsystem is pushed into a regime where small defects become large losses. The following are the engineering problems that separate a true high speed line from a standard line run faster than it should be.
Melt fracture and shark skin at high shear
ライン速度が上がると、ダイランドのせん断速度も上がります。ある臨界せん断速度を超えると、溶融物の表面がシャークスキン状に変化し、低摩擦性の内面仕上げが破壊されます。対処法として、表面粗さRaが0.2マイクロメートル以下の研磨されたダイ流路、200～800ppmのPPAなどの加工助剤を使用して、壁面での有効溶融物の粘度を低下させ、ダイ温度を5～10℃上昇させることで、表面層をランド内で動かすことができます。これらを実行しないと、シリコーン層自体がマットな、破れているような外観を示し、製品の目的を満たせません。
Cooling capacity bottleneck
Cooling load scales with output, not with speed linearly, but at 60 meters per minute the heat released per unit time is about three times that at 20 meters per minute. The vacuum calibration tank and cooling water section must remove that heat before the pipe reaches the haul-off, or the pipe will be soft, oval, and dimensionally unstable. Practically this means extending cooling to 4 or 5 tank sections, raising spray coverage, and running a dual-circuit water system with graded temperatures so the first stage removes the bulk heat and the later stages finish the freeze gently.
真空下でのサイジング安定性と摩擦
高速時、溶融物をキャリブレーションスリーブに保持する真空と、スリーブとパイプ間の摩擦がともに強まります。低速で機能する固定真空設定では、高速時には壁に過度の負荷がかかり、ピックアップ痕やサイジングの不均一性が発生します。解決策は、キャリブレーションスリーブ内の分割真空と低摩擦スリーブコーティングを組み合わせることです。これにより、必要な箇所に真空を適用し、壁を歪ませる可能性がある箇所では真空を解除できます。
Silicone layer uniformity in micro co-extrusion
内面のシリコーン層は、全通過量の2〜5％です。その厚さを0.15〜0.35 mmで設定し、±3％以内で変化させることは、小型エクストルダーで提供されるものよりも精度が高いメートル法安定性が必要とされます。内面層エクストルダーには、ギアポンプまたは高精度な重量計流入装置が組み込まれており、層ゲージ反応がその計量に固有化されるため、ドライフリットがコイルが巻き上げられている後にではなく、数秒以内に駆け回りを修正します。
Closed-loop dimensional control
壁厚の許容範囲はプラス 0.3 mm からマイナス 0 mm です。この速度で許容範囲内に収めるには、閉ループ制御が必要です。レーザー径ゲージは外径を測定し、超音波壁ゲージは壁を測定し、制御システムは目標値を維持するためにハウオフ速度とエキストルーダー出力を調整します。このループに遅れが生じると、コイル全体に沿って周期的な壁の変化が生じます。
Coil ovality and post-extrusion stress
コイル化後、楕円度は5％以下に保たなければなりません。2つの制御要素が重要です。パイプの出口温度は、ワインダーに入る前に35℃以下に保たなければなりませんし、ワインダーの張力は、内側のラップが外側のラップによって圧迫されないように調整する必要があります。ワインダーが一定の張力でパイプを配置し、冷却セクションが目標温度に到達することで、コイルが丸く保たれます。
Process Parameter Reference
以下の表は、高速シリコーンコアダクトラインのプロセスウィンドウの参考値です。値は、試運転中に調整される各樹脂とマスターバッチの組み合わせです。
| Process Stage | パラメータ | Typical Window |
|---|---|---|
| Main barrel zones | 溶融温度 | 180 – 220 deg C across 5 – 7 zones |
| Inner layer extruder | 溶融温度 | 170 – 200 deg C |
| Die head | Head pressure | 15 – 30 MPa |
| Die land | 表面仕上げ | Ra less than or equal to 0.2 micrometer |
| Vacuum calibration | 真空レベル | -0.02 to -0.06 MPa |
| Calibration spray | Water temperature | 12 – 20 deg C |
| Cooling tanks | Gradient | 20 to 15 to 12 deg C |
| Haul-off | ライン速度 | 40 – 80 m/min on high speed line |
| 速度制御 | Sync precision | +/-0.5 percent |
| Exit to winder | Pipe temperature | below 35 deg C |
Quality Standards and In-Line Testing
シリコンコアダクトは、生産中のインライン測定とサンプルの実験による検証によって検証されます。以下の測定対象は、販売可能な通信ダクトを定義するものです。
| Test Item | Acceptance Target | Standard / Method |
|---|---|---|
| 内壁摩擦係数 | mu less than or equal to 0.12 | Friction test on inner surface |
| Air-blowing distance | greater than or equal to 1000 m | Cable jetting trial |
| Hydrostatic resistance | 80 deg C, 165 h | Constant pressure test |
| Longitudinal reversion | less than or equal to 3 percent | 110 deg C reversion test |
| Environmental stress crack | ESCR greater than 2000 h | ASTM D1693 |
| 酸化誘導時間を測定すること | OIT greater than or equal to 20 min | 200 deg C OIT test |
| カーボンブラック分散剤 | Uniform, no agglomerates | Microscopic rating |
| Drop impact | No crack at 0 deg C | Falling weight test |
| Coil ovality | less than or equal to 5 percent | Post-coil measurement |
The governing product standards for communication plastic pipe in China include YD/T 841 for plastic pipe used in communication conduit, with the silicone core series specified within that family. For reference and export, the line is built to be compatible with GB/T 13663 for PE water pipe, ISO 4427, EN 12201, ASTM D3350 for PE pipe materials, and the IEC 60794 family for optical cable related requirements. A producer targeting export markets selects the relevant standard set during line commissioning so the same machine can serve domestic and overseas specifications.
Demand to 回線構成 Recommendation
The table below maps a buyer’s starting requirement to a recommended line configuration. All named equipment belongs to Faygo’s pipe extrusion portfolio, supplied under the Wanplas group umbrella.
| Customer Need | 推奨されるFaygo構成 |
|---|---|
| 32 – 50 mm silicone core duct, medium output, 40 m/min | Faygo パイプ押出 Series base, single-screw 65 mm main extruder, inner-layer co-extruder 30 mm, 2 stripe extruders, spiral mandrel 3-layer die, 6 m calibration plus 2 cooling tanks |
| 40 – 50 mm duct, high output, 60 – 80 m/min | Faygo パイプ押出 Series, single-screw 90 mm main extruder, precision inner-layer metering with gear pump, 4 stripe extruders, extended 4 – 5 cooling tanks, dual-circuit water, high speed 12-track haul-off |
| Multi-hole bundled duct (3/4/7 hole) | Faygo パイプ押出 Series with multi-cavity co-extrusion die head and grouped calibration, integrated winding per tube |
| Flexible corrugated communication conduit | Faygo PE/PP/PVC単層波形パイプ押出ライン, 6 – 200 mm range |
| 電力および通信用のPVCケーブル保護パイプ | Faygo PVCパイプ生産ライン, large diameter varied wall |
| Full turnkey new plant from zero | Faygo factory consulting: water and electricity design, 3D workshop layout, worker training, turnkey build, commissioning |
Line Economics, Energy and Maintenance
技術的な優雅さは、ラインが収益を生み出さなければ意味がありません。ここでの経済性は、相対的な値と物理的単位で表され、決算書の金額としては表されません。なぜなら、装置の価格は構成、目的地、およびタイミングによって異なるからです。
| Economy Factor | Value / Range |
|---|---|
| Specific energy use | 0.28 – 0.42 kWh/kg of pipe |
| High speed advantage | 12 – 20 percent lower kWh/kg versus low speed line |
| Operator per shift | 2 – 3 persons |
| Size changeover time | 40 – 90 min with quick-change die and sleeve |
| Investment index | Baseline single-extruder HDPE silicone core duct line = 100 points; high speed 90 mm line with extended cooling and gear-pump metering rates higher |
| Payback window | Medium; varies with local duct demand and coil price |
The energy story is important. Because a high speed line makes more meters per hour from the same installed power envelope, the energy per kilogram of finished pipe drops by roughly 12 to 20 percent compared with a slower line. Water consumption scales with cooling load and is managed by the chiller and graded tank circuit. Labor is 2 to 3 people per shift thanks to automatic winding and centralized control. Size changeover of 40 to 90 minutes, supported by quick-change die heads and calibration sleeves, keeps the line earning when a customer runs multiple diameters.
Common Defects and Troubleshooting
| 瑕疵 | 考えられる原因 | Corrective Action |
|---|---|---|
| Silicone inner layer peeling | Poor interface fusion, wrong temperature, contaminated masterbatch | Raise interface temperature, dry masterbatch, verify grade match, clean die |
| 壁の偏心率 | Die mandrel offset, uneven cooling, haul-off misalignment | Re-center die, balance spray, align haul-off, tighten closed loop |
| サメの皮の表面 | Excess shear, rough die land, low wall temperature | Polish die to Ra 0.2 micrometer, add PPA 200 – 800 ppm, raise die temp 5 – 10 deg C |
| Bubbles in wall | 樹脂や再生物質の水分量 | Dehumidify dryer 3 h at 80 deg C, seal masterbatch, reduce regrind ratio |
| Color stripe offset | Stripe extruder speed drift, die stripe port clog | Stabilize stripe extruder, clean ports, verify symmetric port geometry |
| Ovality over tolerance | 出口が高すぎ、巻き取り張力が不均一 | 冷却を延長し、35℃以下で終了を確認し、巻取り機の張力を制御する。 |
Faygo Services, Testing and Support
Buying the machine is the start of the relationship, not the end. Faygo delivers its パイプ押出ラインs as customized turnkey solutions and backs them with the shared Wanplas service policy.
- 配送前の72時間の連続運転テストすべてのラインは、出荷前に工場で72時間連続稼働しており、設備導入時の問題は、お客様ではなく、工場内で発見され、修正されます。
- CEおよびISO認定の製造。Faygoのすべての製品は、CEおよびISO規格に準拠しており、長期的な信頼性を確保するために、世界的に有名なブランドの電気部品が使用されています。
- 年間500米ドルの無償スペアパーツ。Wanplasの共通ポリシーに基づき、各ラインに年間500米ドルの無償スペアパーツが提供され、保証期間内の損傷部品の交換も保証されます。
- 24時間365日対応のオンライン技術サポート。リモート診断により、現地訪問の間もラインが稼働し続けます。
- エンドツーエンドサービス。Faygoは、選定、設計、製造、設置、試運転、トレーニング、保守を一つの統合されたプロジェクトとして提供します。
- 工場コンサルティング。工場を新築する場合や設備を更新する場合、Faygoは、水と電気の設計、3Dワークショップレイアウト、作業者の構成とトレーニング、ゼロからの新工場の建設、ダウンタイムなしの古い機械の交換、および設備の拡張を実現し、ボトルネックを解消します。
- オープンファクトリー方針お客様は、上海空港から2時間の距離にある張家港工場を訪れ、26,650平方メートルのFAYGOPLAST施設をご覧になり、ラインが稼働しているのを見ることができます。
22年の経験、3つの専門工場、および8つの発明特許を含む13の国際特許を持つFaygoは、管押出エンジニアリングをシリコーンコア通信ダクトアプリケーションに適用しています。
よくある質問
What is a silicone core cable protection pipe?
It is an HDPE communication duct whose inner wall carries a permanently co-extruded solid silicone lubricant layer. The layer lowers the inner friction coefficient to about 0.05 to 0.12, enabling air-blown cable installation over 1000 to 2000 meters in a single operation.
高速押出は、シリコーンコアダクトにとってなぜ重要なのですか？
Communication duct is a high-volume, price-sensitive product. A high speed line running 40 to 80 meters per minute produces more coils per shift and lowers energy per kilogram by roughly 12 to 20 percent compared with conventional 8 to 20 meters per minute HDPE pipe lines, which improves the whole project economy.
What screw and barrel configuration is used for the main extruder?
The main extruder is a single-screw machine with screw diameter 65 to 90 mm and L/D ratio 33 to 38:1, fitted with a barrier screw and a mixing head such as a Maddock or pineapple style. The barrel has 5 to 7 temperature zones to homogenize the HDPE melt at high output.
シリコーン層は、スループットのわずか2〜5％で均一に保たれています。
The inner-layer co-extruder is paired with a gear pump or a high-precision gravimetric feeder running in a closed loop, holding inner layer thickness at 0.15 to 0.35 mm with variation below plus or minus 3 percent. Layer gauge feedback drives the metering correction in seconds.
Which standards apply to communication silicone core duct?
In China the product is covered by YD/T 841 for communication conduit plastic pipe, with reference to GB/T 13663, ISO 4427, EN 12201, ASTM D3350, and the IEC 60794 optical cable family for export and cable-related requirements.
What cooling setup does a 60 meters per minute line need?
At 60 meters per minute the heat load is about three times that at 20 meters per minute, so the line needs 4 to 5 cooling tank sections, higher spray coverage, and a dual-circuit graded water system stepping from 20 down to 12 degrees C, plus a 6 meter vacuum calibration tank at -0.02 to -0.06 MPa.
How long does a size changeover take and what does Faygo provide?
Changeover runs 40 to 90 minutes with quick-change die heads and calibration sleeves. Faygo supports this with turnkey installation, commissioning, training, 72-hour pre-delivery testing, USD 500 free spare parts per year, and an open factory for inspection.
Can one Faygo line make both silicone core duct and corrugated conduit?
The silicone core duct uses the Faygo パイプ押出 Series with multi-layer co-extrusion, while flexible corrugated communication conduit uses the Faygo PE/PP/PVC単層波形パイプ押出ライン in the 6 to 200 mm range. Both draw on the same Faygo engineering, service policy, and Wanplas group support, so a producer can run them as a coordinated plant.
Conclusion and How to Start Your Project
A silicone core communication duct line is a precision multi-layer co-extrusion system, not a standard pipe line run faster. The science is in the permanently bonded silicone inner layer, the high speed cooling and sizing balance, and the closed-loop dimensional control that holds wall and diameter while the line runs at 40 to 80 meters per minute. Done well, it produces duct that lets operators air-blow optical cable for a kilometer or more in a single pass, which is the real value behind every meter of buried communication network.
Faygo, a Wanplas factory with 22 years of pipe extrusion experience, three specialized factories, 13 national patents including 8 invention patents, and a CE and ISO certified, 72-hour-tested build standard, is positioned to deliver this line as a complete turnkey package. From material system and die head co-extrusion through high speed haul-off, on-line measurement, and automatic winding, the engineering is coordinated under one intelligent control platform and one service policy.
If you are planning a silicone core communication duct plant, or upgrading an existing pipe line to high speed co-extrusion, share your target diameters, required line speed, and daily output with the Faygo team. They will prepare a customized configuration, walk you through factory inspection at the Zhangjiagang site, run a 72-hour demonstration before delivery, and support installation, commissioning, and operator training so your line reaches stable production quickly. You are welcome to visit the factory, review the real machine running, and discuss a tailored turnkey solution for your market.
