A PE silicone core cable protection pipe high speed extruder is the production system that manufactures the smooth, low-friction HDPE duct used to protect and route communication optical cables that are buried directly in the ground. Faygo, a Wanplas factory with 22 years of dedicated experience in plastic pipe and profile extrusion lines, builds these high speed co-extrusion lines for manufacturers who supply telecom operators, highway authorities, railway operators and municipal utilities. This guide explains what a silicon core duct is, how the double-layer co-extrusion system works, what a complete production line contains, which process parameters matter, how to select the right machine configuration, how to inspect the finished pipe, and how to troubleshoot the most common defects. Whether you are planning a new facility, replacing aging equipment, or expanding capacity, the information below gives you a concrete technical foundation for specifying a high speed extrusion line that produces reliable communication optical cable protection pipe.
The demand for buried optical cable duct keeps rising because fiber-to-the-home, 5G mobile backhaul, data center interconnection and smart-grid communication all depend on protected, easily upgradeable cabling routes. Conventional smooth HDPE duct can only be installed by pulling, which is slow, damages the cable jacket, and limits the length of a single installation section. The silicone core pipe solves this by placing a permanent solid silicone lubricant layer on the inner wall during extrusion, so the cable is installed by air-blowing over distances of 1000 to 2000 meters in a single operation. Producing that inner layer consistently at high line speed is exactly what a well-designed high speed extruder must deliver, and that is the focus of this article.
What Is a PE Silicone Core Cable Protection Pipe
A PE silicone core cable protection pipe, also called a silicon core duct or HDPE silicon core duct, is a high-density polyethylene conduit with a co-extruded solid silicone lubricant layer permanently bonded to its inner surface. The base tube is made from pipe-grade HDPE, while the inner layer is a thin film of silicone compound, typically 0.05 to 0.15 millimeters thick, that is extruded together with the base layer in a single pass through a multi-channel die head. The result is a single-wall duct that combines the mechanical strength and weatherability of HDPE with the permanent low friction of silicone.
The defining performance metric is the inner-wall dynamic friction coefficient. A normal HDPE pipe has a dynamic friction coefficient of about 0.35 to 0.45 against a cable jacket, which is too high for long air-blown installation. A qualified silicon core duct reduces this to 0.08 or lower. At that friction level, a compressor can blow a lightweight optical cable through the pre-laid duct at several meters per second, placing 1000 to 2000 meters of cable in one continuous operation without pulling ropes, grease, or intermediate manholes. This installation method is known as air-blown cable installation, and it is the main reason telecom operators specify silicon core duct for new networks.
The duct is produced in fixed nominal sizes expressed as outer diameter over inner diameter. The most common communication specifications are phi32/26, phi40/33, phi46/40 and phi50/41, where the first number is the outer diameter and the second is the inner diameter in millimeters. Color identification stripes, usually three or four longitudinal stripes, are co-extruded on the outer wall so that different cable routes can be distinguished inside a shared trench. The table below maps the standard specifications to wall thickness, the maximum cable outer diameter that can be installed, and the typical coil length used for transport and deployment.
Standard 仕様書 and Coil Length Reference
| 仕様書 (OD/ID, mm) | Nominal Wall Thickness (mm) | Max. Installed Cable OD (mm) | Standard Coil Length (m) | Typical Color Stripes |
|---|---|---|---|---|
| phi32/26 | 3.0 | 24 | 1000 / 1500 / 2000 | 3 |
| phi40/33 | 3.5 | 30 | 1000 / 1500 | 3 or 4 |
| phi46/40 | 3.0 | 36 | 1000 | 3 or 4 |
| phi50/41 | 4.5 | 38 | 1000 | 4 |
The wall thickness is determined by the difference between the outer and inner diameters divided by two, and it must stay within tolerance because both ring stiffness and the available cable clearance depend on it. The HDPE base provides the structural performance, while the thin silicone layer does none of the load bearing yet delivers almost all of the installation advantage. Because the silicone layer is so thin, holding its thickness and continuity across the full length of a high speed run is the central manufacturing challenge addressed later in this article.
Why Silicone Core Duct Outperforms Conventional Single-Layer Duct
Silicon core duct changes the economics of underground communication cabling because it moves the friction problem from the installation crew to the factory. A conventional single-layer HDPE duct relies on the base polymer surface, which is relatively rough and has a high friction coefficient. Cable placement therefore requires pulling grips, rope, and often periodic application of liquid lubricant, with short achievable lengths and a real risk of jacket damage. The silicon core duct replaces all of that with a factory-applied permanent lubricant surface.
The comparison below is a technology-to-technology comparison, not a brand comparison. It contrasts the silicon core co-extruded duct with the conventional single-layer duct that older lines still produce. This distinction matters when you evaluate whether to invest in a dedicated high speed silicon core extrusion line rather than adapting a standard pipe line.
| 形状 | PE Silicon Core Duct | Conventional Single-Layer Duct |
|---|---|---|
| 内壁摩擦係数 | 0.08 or lower (dynamic) | 0.35 to 0.45 |
| Cable installation method | Air-blown, 1000 to 2000 m per blow | Pulling, short sections |
| Lubrication | Permanent solid silicone layer | Periodic liquid lubricant |
| 設置速度 | High, continuous | Low, step by step |
| Cable jacket damage risk | Low | Higher under pull load |
| Network upgrade convenience | Re-blow new cable anytime | Re-pull, more labor |
| Required line technology | Multi-layer co-extrusion die head | Single-layer standard die |
For the operator, the practical benefit is lower total installed cost per meter of fiber route, faster project completion, and the ability to add capacity later simply by blowing in another cable. For the pipe manufacturer, however, the benefit comes with a manufacturing obligation: the silicone layer must be continuous, uniform and well bonded, and it must survive coiling, transport, trench laying and decades in the ground. That obligation drives every design decision in the extrusion line.
The Double-Layer Co-Extrusion System
The core of a silicon core pipe extruder is a double-layer, or more precisely a multi-layer, co-extrusion system. The outer and main HDPE structure is produced by the primary extruder, while a thin silicone layer is fed by a dedicated small co-extruder into the same die head so that the two materials merge at the die land and exit as one unified pipe. A third, even smaller extruder may add the colored identification stripes on the outer surface. All three melt streams meet in a three-channel co-extrusion die head that is the heart of the technology.
The primary extruder is a single-screw machine, most often sized at 65 millimeters in diameter with a 33-to-1 length-to-diameter ratio, or scaled up to 75 millimeters diameter and 33 L/D for higher output. The screw uses a barrier design combined with a mixing head so that the HDPE melts uniformly, degasses, and builds stable pressure. Output from this machine typically ranges from 250 to 450 kilograms per hour depending on screw size and screw speed. A barrier screw with a dispersive mixing section is important because silicone masterbatch and color masterbatch are added at low percentages and must be distributed without streaks.
The silicone core co-extruder is a much smaller machine, commonly 30 millimeters diameter with 25 L/D, or 35 millimeters diameter with 25 L/D on high speed lines. It plasticizes the silicone compound at a controlled temperature and delivers a precise, low-volume melt into the inner channel of the die head. Because the silicone layer is only 0.05 to 0.15 millimeters thick, the metering accuracy of this small extruder directly controls product quality. The stripe co-extruder is even smaller, typically 20 to 25 millimeters in diameter, and it lays the colored identification stripes on the outer wall.
The three-channel die head is where the technology is won or lost. Its flow channels must keep the HDPE and silicone melts at their correct, separate temperatures until the very last moment, then join them so the silicone forms a uniform, concentric inner skin with strong interfacial bonding. Two engineering targets dominate die design. First, silicone layer uniformity: the layer thickness must stay within a tight band along the entire pipe length and around the circumference, otherwise local friction rises and air-blown performance becomes inconsistent. Second, interfacial bonding: the peel strength between the silicone layer and the HDPE base must be high enough that the layer never delaminates during coiling, bending, or installation, yet the two materials must not inter-diffuse into a mushy boundary.
Faygo supplies this co-extrusion system as part of its high speed PE silicon core パイプ押出ライン, built on the same pipe extrusion platform that covers 12 to 575 millimeter diameters for water, gas, drainage and communication applications. The Faygo line uses internationally recognized brand electrical components and an intelligent control system that lets the operator set and adjust parameters in real time. The table below presents two Faygo configuration tiers for communication silicon core duct, drawn from the standard machine sizes used for this product family.
Die head temperature control deserves special attention because the HDPE and silicone melts have different thermal windows and must not be allowed to mix too early. The head is typically heated in independent zones so the operator can hold the HDPE channels near 200 to 215 Celsius while keeping the silicone channel in its narrower 180 to 200 Celsius band. 溶融圧力 at the die is monitored so that fluctuations, which would otherwise translate into wall thickness variation, are caught immediately. A well-built three-channel head also makes the silicone layer adjustable independently of the base wall, which is the feature that lets one line serve both thin phi32/26 duct and thicker phi50/41 duct without changing the fundamental low-friction performance.
Faygo High Speed Silicon Core パイプ押出ライン 仕様書s
| アイテム | Standard Speed Configuration | High Speed Configuration |
|---|---|---|
| Applicable pipe OD | phi32/26, phi40/33 | phi40/33, phi46/40, phi50/41 |
| Main extruder screw | Single-screw 65 mm, 33 L/D, barrier + mixing head | Single-screw 75 mm, 33 L/D, barrier + mixing head |
| Silicone core co-extruder | 30 mm, 25 L/D | 35 mm, 25 L/D |
| Stripe co-extruder | 20 mm | 25 mm |
| Maximum throughput | 250 to 320 kg/h | 380 to 450 kg/h |
| Maximum line speed | 30 m/min | 45 m/min |
| インストール電力 | Approx. 145 kW | Approx. 185 kW |
| Total line length | Approx. 36 m | Approx. 42 m |
| Calibration method | Vacuum calibration, minus 0.02 to minus 0.05 MPa | Vacuum calibration, minus 0.02 to minus 0.06 MPa |
| Haul-off type | Caterpillar haul-off, 15 to 30 m/min | Caterpillar haul-off, 15 to 45 m/min |
The downstream auxiliary equipment deserves its own specification view because it determines whether the high speed potential of the extruder is actually realized on the floor. The vacuum calibration box, spray cooling tanks, caterpillar haul-off, ink-jet printer with meter counter, dual-station chip-free cutter and automatic coiling winder must all keep pace with the die output. The table below lists the auxiliary unit parameters that Faygo configures to match the two main line tiers.
Faygo Downstream Auxiliary Unit 仕様書s
| Auxiliary Unit | Standard Speed Configuration | High Speed Configuration |
|---|---|---|
| Vacuum calibration box | Single stage, water 15 to 20 Celsius | Extended stage, water 15 to 20 Celsius |
| Cooling method | Multi-stage spray cooling tank | Longer multi-stage spray cooling tank |
| Haul-off grip length | Standard caterpillar length | Extended caterpillar length for high pull |
| Printer and meter counter | Ink-jet, length metering | Ink-jet, length metering |
| カッター | Dual-station chip-free cutter | Dual-station chip-free cutter |
| Coiling winder | Automatic, coil diameter 1000 to 2000 mm | Automatic, coil diameter 1000 to 2500 mm |
Complete Production 回線構成 Chain
A complete high speed silicon core パイプ押出ライン is a sequence of synchronized units, each responsible for one stage of converting HDPE pellets, silicone masterbatch and color masterbatch into coiled finished duct. Understanding the chain helps you plan the factory layout, utility supply and operator workflow. The chain runs as follows.
Centralized feeding delivers the HDPE base material, silicone masterbatch and color masterbatch to the correct extruder hoppers. Gravimetric or volumetric dosing keeps the low-percentage silicone and color additions accurate, which is essential for layer uniformity. The primary and secondary extruders then plasticize their respective melts. The three-channel co-extrusion die head and its tooling, consisting of the die and the core rod, set the final pipe geometry. The gap between the die and the core rod, together with the draw-down ratio, controls wall thickness and concentricity. After the die, the molten pipe enters the vacuum calibration box.
The vacuum calibration box fixes the outer diameter by drawing the soft pipe against a cooled calibration sleeve under vacuum. The vacuum level is held at minus 0.02 to minus 0.06 megapascal, and the cooling water is kept at 15 to 20 Celsius so the surface sets quickly without thermal shock. From calibration the pipe passes through a multi-stage spray cooling water tank where the wall is fully solidified. The caterpillar haul-off then pulls the pipe at a controlled, steady speed. Because the haul-off speed sets the draw-down, it is the master variable that couples extruder output to final dimensions.
After cooling, an ink-jet printer applies identification and a meter counter records length. The dual-station chip-free cutter cuts the pipe at the programmed coil length without generating debris that could contaminate the duct. Finally, an automatic coiling winder winds the pipe onto reels of 1000 to 2500 millimeters diameter, depending on the pipe size and the transport coil length selected. The synchronization of extruder output, haul-off speed and cutter timing is managed by the line control system so that wall thickness, length and coil weight stay consistent across the whole production run.
From a layout perspective, the standard configuration occupies about 36 meters of floor length and the high speed configuration about 42 meters, plus space for material storage, coil handling and finished-goods staging. Faygo’s factory consulting service can provide water and electricity design, three-dimensional workshop layout, worker configuration and training as part of a turnkey project, which is especially useful for a new facility built from zero.
Process Parameters and Settings
Stable, repeatable process parameters are what separate a high speed line that produces qualified silicon core duct from one that produces scrap. The parameters span material selection, barrel temperature profile, die head temperature, silicone temperature, vacuum, cooling water temperature, haul-off speed and draw-down ratio. The table below consolidates the working window for communication silicon core pipe.
Process Parameter Window
| Stage / Parameter | Range / Setting | Notes |
|---|---|---|
| HDPE grade | PE80 / PE100 pipe material | MFR 0.2 to 0.6 g/10 min at 190 Celsius, 5 kg; density 0.945 to 0.955 |
| Barrel zone 1 temperature | 170 to 185 Celsius | Feed and compression |
| Barrel zone 2 temperature | 185 to 195 Celsius | Melting |
| Barrel zone 3 temperature | 195 to 205 Celsius | Mixing |
| Barrel zone 4 temperature | 200 to 210 Celsius | Metering |
| Die head temperature | 200 to 215 Celsius | Uniform across head |
| Silicone material temperature | 180 to 200 Celsius | Stable for thin layer |
| Calibration vacuum | minus 0.02 to minus 0.06 MPa | Sets outer diameter |
| 調整水 temperature | 15 to 20 Celsius | Fast surface set |
| ハウルオフスピード | 15～40 m/min, high speed 45 | Matches throughput |
| Draw-down ratio (DDR) | 1.2 to 1.6 | Controls wall thickness |
| Main screw speed | 20 to 60 rpm | Tune with haul-off |
Several parameter relationships deserve emphasis. The barrel temperature must increase gradually from feed to metering so that the HDPE melts without degradation; an overheated rear zone degrades the material while an underheated front zone causes melt fracture and a rough surface. The silicone melt must stay in its own narrow band so the thin layer forms smoothly; too cold and it streaks, too hot and it loses definition at the interface. The calibration vacuum and the haul-off speed together control outer diameter and wall thickness, so they are the first things to check when dimensions drift.
引き下げ比は、ダイ開口部の断面積と完成パイプの断面積の比で定義され、シリコンコアダクトの場合、通常 1.2 から 1.6 です。高い引き下げ比は、壁を細くし、ライン速度を上げますが、応力を高め、シリコーン層を不均一に薄くする可能性があります。低い引き下げ比は穏やかですが、指定された壁厚と利用可能なエクストラクター出力と最大安全ハウルオフ速度をバランスさせることで正しい値が見つかります。
How to Select the Right Faygo Line for Your Project
Selecting the right extrusion line starts from the pipe sizes you must supply and the daily output you must achieve. A manufacturer serving a regional telecom program with mostly phi32/26 and phi40/33 duct can run a standard speed line efficiently, while a supplier covering highway and railway programs with larger phi46/40 and phi50/41 duct, or one pursuing maximum throughput, should choose the high speed configuration. The recommendation table below maps common project requirements to the Faygo configuration that fits them.
Requirement to Configuration Recommendation
| Target Pipe OD | Daily Output Target | Coil Length Requirement | 推奨されるFaygo構成 |
|---|---|---|---|
| phi32/26 | 8 to 12 km/day | 2000 m coils | Standard speed 65 mm line |
| phi40/33 | 10 to 15 km/day | 1500 m coils | Standard or high speed 65 mm line |
| phi46/40 | 12 to 18 km/day | 1000 m coils | High speed 75 mm line |
| phi50/41 | 12 to 20 km/day | 1000 m coils | High speed 75 mm line |
| Mixed sizes | Flexible | Mixed | High speed line with quick-change tooling |
直径と出力に加えて、ユーティリティ容量も考慮する必要があります。高速ラインは 185 キロワットのインストール電力を消費し、15 から 20 摂氏の安定した冷却水供給が必要です。そのため、サイトは十分な電力供給と冷却塔またはチラーを提供する必要があります。コイルハンドリングも重要です。大きな 2500 ミリメートルのコイルは重く、ワインダーと倉庫の両方で適切なハンドリング機器が必要です。プログラムが複数の直径をカバーしている場合、クイックチェンジダイとコアロッドツールを導入して、変更が短く、ライン使用率が高く維持できます。
Wanplas ファクトリーである Faygo は、関連するニーズに対する広範な Wanplas グループの能力を利用することもできます。これには、材料取り扱い、投与、および集中制御が含まれ、カスタマイズされたターンキーソリューションとして提供され、個別の製品名ではなく Wanplas ブランドファミリーの一部として提供されます。これにより、プロジェクトが単一ソースで、責任をもって維持され、同時に Wanplas ブランドファミリー内に留まります。
Quality Inspection and Acceptance Tests
Silicon core duct is judged by a specific set of tests because its value depends on the inner wall as much as on the structure. The most important test is the inner-wall friction coefficient, measured on an air-blow simulation bench that reproduces the installation condition; a qualified duct shows a dynamic friction coefficient of 0.08 or lower. リングの硬さ confirms the duct can resist soil load, while the falling weight impact test verifies toughness at low temperature. Longitudinal reversion, measured at 110 Celsius for one hour, must not exceed 3 percent, confirming the pipe will not shrink excessively in service. The hydrostatic test confirms the wall integrity under pressure, and the silicone layer is checked for peel strength and scratch resistance so it stays bonded and intact.
Factory Inspection Items and Acceptance Criteria
| Test Item | Method / Reference | Acceptance Criterion |
|---|---|---|
| 内壁摩擦係数 | Air-blow simulation bench | Dynamic 0.08 or lower |
| リングの硬さ | リングの硬さ test | Per stiffness class |
| Falling weight impact | Falling weight impact test | No crack at low temperature |
| Longitudinal reversion | 110 Celsius, 1 hour | 3 percent or less |
| Hydrostatic pressure | Hydrostatic test | No failure at rated pressure and time |
| Silicone layer peel and adhesion | Peel test | No delamination |
| Scratch resistance | Scratch test | Silicone layer remains intact |
| Inner wall roughness Ra | Profilometer | Low, smooth surface |
| Wall thickness and eccentricity | Ultrasonic or cut section | Within specification tolerance |
| Outer diameter and ovality | Caliper or gauge | Within specification tolerance |
| Color stripe continuity | Visual and continuity check | Continuous, identifiable |
これらのテストは、生産ランで継続的にサンプリングされる必要があり、単に終了時にではなく、パラメーターがドリフトしたときに不具合が出現するためです。Faygos の品質管理には、出荷前に 72 時間の連続運転テストが含まれ、製品仕様を満たすことができることを確認するために、製品パスのもとで製造条件でラインを動作させます。
Common Defects and Troubleshooting
Even a well-designed line produces defects when parameters drift, tooling wears, or material varies. The table below lists the defects most often seen in silicon core pipe production, their typical causes, and the corrective action. A disciplined operator uses this as a daily reference and treats any rise in air-blow resistance as a top-priority signal because it directly defeats the product’s purpose.
Defect, Cause and Remedy Reference
| 瑕疵 | 典型的な原因 | Corrective Action |
|---|---|---|
| Silicone layer discontinuous or streaked | Uneven silicone masterbatch feed, wrong melt temperature | Stabilize dosing, adjust silicone temperature to 180 to 200 Celsius |
| Inner wall bulge | Uneven cooling, poor concentricity | Check calibration vacuum, re-center die and core rod |
| 壁厚の偏心率 | Core rod misaligned, uneven heating | Realign die and core rod, balance barrel zones |
| Out-of-round ovality | Insufficient vacuum, haul-off speed mismatch | Raise vacuum, balance puller speed with output |
| Color stripe drift | Stripe extruder position offset | Adjust stripe co-extruder position and output |
| Coil spring-back and recoil | High residual stress, too-fast cooling | Slow cooling, use larger coil diameter |
| High air-blow resistance | Rough inner wall, non-uniform silicone | Check silicone layer, polish die land, verify Ra |
| Silicone delamination | Poor interface bonding | Increase interface temperature, optimize layer ratio |
| Surface roughness or shark skin | Melt fracture, temperature too low | Raise barrel and die temperature, adjust screw speed |
| Black spots or contamination | Material contamination or degradation | Filter melt, clean barrel, check screen changer |
| 外径変動 | Unstable haul-off, pressure fluctuation | Use closed-loop speed control, stabilize melt pressure |
| Poor stripe adhesion or fading | Wrong pigment, weak bonding | 互換性を確保したマスターバッチを使用し、温度を確認してください。 |
| Bubbles inside wall | Moisture, trapped gas | Dry material, use vented barrel zone |
| Low ring stiffness | Wall too thin, low grade material | Verify wall thickness, use PE100 pipe grade |
Most of these defects trace back to three root causes: unstable metering of the low-percentage additives, a die or core rod that is not concentric, and a calibration or haul-off section that is not synchronized with the extruder. A preventive maintenance routine that checks dosing accuracy, die alignment and vacuum stability every shift will eliminate the majority of scrap before it starts.
適用分野 and Deployment Scenarios
Communication optical cable protection pipe serves a broad set of deployment scenarios, all of which benefit from the air-blown installation that silicon core duct enables. Faygo’s パイプ押出ラインs are applied across water supply, drainage, gas, communication and agricultural irrigation, and the communication and power cable protection segment is a core application of its pipe product family. The concrete scenarios for silicon core duct are described below.
長距離トランク光ケーブルの直接埋設は、古典的な用途です。全国的および地方的なバックボーンネットワークは毎年、数千キロメートルのダクトを敷設し、1000～2000メートルのケーブルを1回の作業で吹き込むことができるため、マンホール数と労力を大幅に削減できます。都市および自治体の配管通信では、電気通信、電力、その他のサービスを区別するためにダクト内に共用公益施設のトレンケを使用します。高速道路および鉄道コルライド通信では、ダクトを路床または権限線路に沿って配置し、将来的に容量を追加することなく舗装を掘削することなく配線できます。キャンパスおよび公園の弱電配線ネットワークでは、ビル間ファイバー用のシリコンコアダクトを使用し、頻繁なアップグレードにより、エアーブロウインストールが特に価値があります。最後に、5G基地局バックホールは、アンテナサイトから集約ノードまでの保護されたファイバに依存し、高速で低リスクのルーティングが、密集した小セル展開に必要です。
各シナリオでは、パイプは数十年にわたって地下に埋められ、土圧や湿気に耐え、設置中および後で機械的な干渉からケーブルを保護する必要があります。HDPEベースは耐候性と耐薬品性を提供し、シリコーンコアは設置の柔軟性を提供します。これらの市場にサービスを提供するメーカーは、ラインの一貫性と摩擦試験をほとんどの他の品質指標よりも優先すべきです。
The deployment environment also shapes the specification choices a buyer should discuss with the equipment supplier. In long-haul and highway projects the duct is often laid in sandy or rocky backfill, so wall thickness and ring stiffness class must match the burial depth and traffic load, and the color stripes must stay visible after years of trench handling. In city and campus networks the duct shares trenches with power and water lines, which raises the importance of clean identification and of a smooth inner wall that supports repeated re-blowing as bandwidth demand grows. For 5G backhaul, rollout speed is often the deciding factor, and the air-blown method lets operators light a route quickly and add fibers later without new excavation. A producer who understands these differences can stock the right diameter mix, phi32/26 through phi50/41, and tune the line to switch between them with minimal downtime.
メーカー側からすると、複数のシナリオに対応することは、材料ロジスティクスを慎重に計画することも意味します。パイプグレードのPE80とPE100は、天然または前加工されたペレットとして供給され、シリコーンとストライプマスターバッチは低割合で添加されるため、投入および保管システムは、各添加物を清潔で乾燥した状態に保つ必要があります。わずかな量の汚れや湿気を含んだ材料は、黒い斑点、気泡、またはストライプを生じさせ、摩擦および外観テストに合格しません。合理的な社内慣例には、各成分のために別々のシロアリまたは屋根付きの籠が用意されていること、ベース樹脂の湿度を定期的に確認すること、およびパイプサイズや色の変更時の文書化された変更手順が含まれます。これらの慣例は、その投資を保護し、高速ラインの出力が販売可能であることを保証します。
Services and Technical Support
エクストルーダーラインを購入することは、長期間の生産関係の開始であり、サポートサービスは、機器が約束された出力を達成するかどうかを決定します。Wanplas工場のFaygoは、サポートをいくつかの具体的なコミットメントに基づいて構築しています。納品前に、すべてのラインは72時間の連続運転テストを受けます。これにより、設定問題が工場で発見され、お客様のサイトで発生しないようになります。その後、エンジニアがお客様固有の材料とパイプサイズのプロセスパラメータを設定するために、ラインが設置および試運転されます。
スペアパーツポリシーでは、年間500米ドルの無料スペアパーツが提供され、保証期間内の損傷した部品は無料で交換されます。技術サポートは、オンラインチャネルを通じて常時利用可能であり、夜間シフト中にパラメータの振れが見られる場合に特に重要です。オペレータトレーニングでは、マシン操作、日常的なメンテナンス、ダイ交換、および基本的なトラブルシューティングがカバーされ、お客様のチームが自立できるようになります。リモート運用およびメンテナンス機能により、工場は遠隔地からラインの問題を診断し、ダウンタイムを短縮できます。
Faygo also operates an open-factory policy and welcomes customer visits for inspection, discussion and sample trial runs. A prospective buyer can send material and target specifications, watch the line produce sample duct, and verify the friction and dimensional performance before committing. For greenfield projects, factory consulting services cover water and electricity design, three-dimensional workshop layout, worker configuration and training, and can deliver a new factory as a turnkey project built from zero. Existing plants can use the old machine replacement and capacity expansion services to upgrade without prolonged downtime.
よくある質問
What is a PE silicone core cable protection pipe?
It is an HDPE duct with a co-extruded solid silicone lubricant layer on the inner wall. The silicone layer lowers the dynamic friction coefficient to about 0.08 so optical cables can be installed by air-blowing over long distances instead of being pulled.
エアブローンケーブル設置は、シリコンコアダクトでどのように行われますか？
コンプレッサーは、永久的な低摩擦シリコンオリヤーを使用して、事前に敷設されたダクト内にケーブルを送ります。1回の打撃で、1000メートルから2000メートルのケーブルを配置できます。ロープを引くことや定期的な潤滑は不要であり、ケーブルジャケットに対する圧力は低くなります。
What HDPE grade is used for silicon core pipe?
Pipe-grade PE80 or PE100 materials are used, with melt flow rate 0.2 to 0.6 grams per 10 minutes measured at 190 Celsius under 5 kilograms, and density in the range 0.945 to 0.955.
What production line speed can a high speed extruder reach?
A standard speed line runs 15 to 30 meters per minute, while a high speed line driven by a 75 millimeter, 33 L/D 単一スクリュエキストラクター reaches up to 45 meters per minute, depending on pipe size and wall thickness.
How many color stripes are needed and what do they mean?
通信ダクトのほとんどは、外壁に3つまたは4つの縦方向の色のストライプを共同押出ししています。これらは、共有トレンチ内の異なるケーブルルートまたはオペレータを識別し、全コイルにわたって連続しています。
What is the typical draw-down ratio for silicon core pipe?
The draw-down ratio normally sits between 1.2 and 1.6. It is set by the die opening and the haul-off speed and directly controls wall thickness, so it must be balanced against extruder output and the maximum safe line speed.
How is product quality verified before shipment?
Faygo performs 72-hour continuous operation testing before delivery, checking friction, wall thickness, roundness, impact and hydrostatic performance, then provides installation, commissioning and operator training to confirm the line meets the project specification.
What after-sales support does Faygo provide?
Support includes a USD 500 free spare parts allowance per year, warranty replacement, 24/7 online technical help, remote diagnostics, on-site commissioning and an open-factory policy for visits and sample trials.
結論
A PE silicone core cable protection pipe high speed extruder is a specialized co-extrusion system built to manufacture the low-friction HDPE duct that makes air-blown optical cable installation practical. The technology rests on a three-channel die head that bonds a 0.05 to 0.15 millimeter silicone layer to the HDPE inner wall, a synchronized chain from centralized feeding through vacuum calibration, spray cooling, caterpillar haul-off, printing, chip-free cutting and automatic coiling, and a disciplined set of process parameters that hold the friction coefficient at 0.08 or lower. Faygo, a Wanplas factory with 22 years of pipe and profile extrusion experience, three specialized factories, 26,650 square meters of production space in Zhangjiagang, 13 national patents and CE and ISO certification, supplies these lines in standard speed and high speed configurations covering phi32/26 through phi50/41 duct.
If you are planning a new silicon core duct facility, expanding an existing line, or replacing aging equipment, the right next step is to share your target pipe sizes, daily output and coil length with our engineering team. We can configure a complete line to your specification, run sample duct on the floor for your verification, and support you from factory layout through commissioning and operator training. You are welcome to visit the factory, inspect the line, and trial the equipment with your own material before making a decision.
