Supplying domestic hot water to a building that rises one hundred meters or more is a mechanical problem long before it becomes a plumbing problem. The column of water alone loads the lowest floors with static pressure that a conventional low-rise distribution system was never designed to see, while the continuous hot service temperature silently attacks every joint, every elbow and every meter of pipe wall over a design life measured in decades rather than years. In this environment the pipe is not a passive conduit; it is a structural and hygienic component that must hold pressure, resist temperature, refuse to scale, and survive for fifty years without a single interruption. A three layer composite anti scaling PPR pipe extrusion equipment exists precisely because a single homogeneous pipe wall can no longer satisfy all of those duties at once.
The engineering answer is to stop asking one material to do everything and instead assign each function to a dedicated layer. A three-layer composite PPR pipe places an anti-scaling functional layer on the bore, a reinforcement or barrier layer in the middle, and a protective layer on the outside, co-extruding all three through one die in a single pass. The equipment that makes this pipe is therefore more than a パイプ押出ライン with extra hoppers; it is a tightly synchronized co-extrusion system in which layer ratio, melt viscosity, die geometry and cooling rate must be controlled together. This guide explains the full picture for equipment buyers and project engineers: why high-rise hot water demands the composite structure, how the three layers function, which materials and standards apply, exactly how the production line is built, what the process window looks like, how anti-scaling performance is measured, how the pipe is integrated into a tall building, and which Faygo production lines deliver it.
Faygo, a Wanplas factory with twenty-two years of dedicated pipe and profile extrusion experience, operates three specialized factories and runs a 26,650 square metre pipe, profile and sheet plant in Zhangjiagang, only two hours from Shanghai airport. The factory holds thirteen national patents including eight invention patents, and every line leaves the workshop CE and ISO certified after seventy-two hours of continuous operation testing. As part of the Wanplas group, Faygo draws on a shared engineering and service backbone that has placed plastic machinery in more than one hundred exported regions. The three-layer PPR co-extrusion line described here is a direct application of that experience to the specific failure modes of high-rise domestic hot water.
1. Four Hardships Facing 家庭用温水 Systems in High-Rise Buildings
A high-rise domestic hot water network is defined by four stresses that ordinary low-rise plumbing never experiences together. Each stress alone is manageable; the four acting simultaneously on a single pipe wall are what make the composite structure necessary. Understanding these four hardships is the first step in specifying the right extrusion equipment, because the equipment must be capable of producing a pipe that answers all four at once.
1.1 Static pressure at the base of a tall column
In a building one hundred meters tall, the static head of the water column at the lowest riser connection is close to one megapascal before any pump pressure is added. With distribution pumps and thermal expansion, the bottom-floor service pressure in a one-hundred-meter building commonly reaches 1.0 to 1.2 megapascal. A single-layer random copolymer pipe sized for low-rise duty would need a very thick wall to carry that pressure, which only worsens the next two problems. The composite structure lets the middle layer carry stiffness and the inner layer carry the bore condition independently, so the pressure requirement does not force an oversized, thermally sluggish wall.
1.2 Long-term continuous hot water temperature
Domestic hot water is not a gentle, intermittent service. Circulation systems hold the riser at a continuous 60 to 70 degrees Celsius so that a tap delivers hot water promptly, and safety events such as a failed mixing valve can push short-term peaks to 95 degrees Celsius. Polypropylene random copolymer tolerates this band, but sustained temperature accelerates creep, softens the wall, and accelerates every chemical reaction at the bore, including scale deposition. The equipment must therefore extrude a pipe whose long-term hoop stress rating remains adequate at elevated temperature, which is why PP-RCT with its raised minimum required strength is offered as an inner-layer option.
1.3 Scaling and biofilm formation on the bore
Hard water carrying dissolved calcium and magnesium bicarbonate deposits calcium carbonate on any surface where nucleation can start. A rough bore, a polar surface, and warm stagnant pockets are ideal nucleation sites. Over years the deposit narrows the bore, raises flow resistance, and provides a habitat for biofilm. The inner anti-scaling functional layer of the composite pipe attacks this at the source: a mirror-smooth, low-surface-energy, optionally antibacterial bore that gives calcium carbonate almost nowhere to begin. This is the single most important reason the pipe is composite rather than homogeneous, and it is the property that the extrusion equipment must hold to tight tolerance across the full length.
1.4 Fifty-year design life
Building services are not replaced on a whim. A riser buried in a wall chase or a shaft is expected to perform for the life of the building, typically fifty years, with no access for inspection and no tolerance for leakage. Fifty years of pressure, temperature cycling, thermal movement and water chemistry demands a pipe whose properties do not drift. The three-layer composite answers this through material selection, expansion control and a protected outer surface, and the extrusion equipment must reproduce that layered structure meter after meter with no delamination that could become a long-term failure path.
When all four hardships act on one wall at once, the only robust answer is to separate functions into layers. That separation is exactly what three-layer co-extrusion equipment is built to deliver.
2. Functional 層構造 of the Three-Layer Composite Anti-Scaling PPR Pipe
The three-layer composite PPR pipe is engineered as three concentric functional zones, each optimized for one job and bonded to its neighbor by a compatible or tie-mediated interface. The layer ratio is deliberately imbalanced: the middle layer carries most of the wall because it carries most of the structural and barrier duty, while the inner and outer layers stay thin because they are functional skins rather than load-bearing members. The typical split is about 20 to 25 percent inner, 50 to 60 percent middle, and 20 to 25 percent outer by wall thickness.
2.1 Inner layer: the anti-scaling functional skin
The inner layer is the surface that touches the water, so its entire design goal is to make scale and biofilm unwelcome. Three mechanisms are combined. First, the bore is finished to a high smoothness with inner wall roughness Ra not more than 0.3 micrometer, compared with 0.8 to 1.5 micrometer for ordinary PPR, because fewer surface asperities means fewer nucleation sites for calcium carbonate crystals. Second, the polymer is modified for anti-fouling, either by an antibacterial additive package that suppresses microbial film or by a low-surface-energy modification that makes the water wet the wall uniformly instead of pinning droplets and deposits. Third, where temperature permits, the inner layer can be made from PP-RCT, the beta-crystal nucleated random copolymer, which raises the long-term temperature rating of the bore itself. Because this layer is thin, a premium modified compound can be used without making the whole pipe expensive.
2.2 Middle layer: reinforcement or barrier
The middle layer is the structural heart of the wall and the place where the designer chooses the dominant property the building needs. Two options dominate. The first is glass-fiber reinforced PP-R, loaded with 10 to 20 percent glass fiber, which cuts the linear expansion coefficient from about 0.15 to 0.03 to 0.05 millimeter per meter per Kelvin. For a vertical riser dozens of meters long, that reduction is decisive: it shrinks thermal movement, reduces the number and size of fixed supports and expansion compensators, and keeps the pipe from bowing in its chase. The second option is EVOH (ethylene vinyl alcohol copolymer), an oxygen barrier used when the line is part of a closed heating circuit and must prevent oxygen from diffusing through the wall and corroding metal pumps, valves and radiators. With EVOH the oxygen permeability stays below 0.1 gram per cubic meter per day, satisfying the DIN 4726 limit for oxygen-tight plastic pipes. The choice between glass fiber and EVOH is a design decision made before the line is configured, and the co-extrusion equipment supports either.
2.3 Outer layer: protection and identification
外層は、パイプの世界との皮膚です。紫外線安定剤を配合することで、パイプが設置前の保管や一時的な露出に耐えられるようになります。また、耐擦傷性を持つため、設置時に傷がつきにくくなります。さらに、色やストライプによる識別が可能になるため、インストール者は通常のPPRと異なるスケール防止コンポジットパイプを一目で区別できます。また、プラントルームなどに露出する部分には、耐候性のある表面を備えます。薄い皮膚であるため、構造層や衛生層に影響を与えずに色やストライプを付けることができます。そのため、コンポジットパイプは特殊製品であることが目に見えるようにマークされています。
2.4 Layer ratio and co-extrusion temperature matching
Holding the layer ratio constant along the full line is the central quality task of the equipment. The three melts have different viscosities and thermal sensitivities, so the co-extrusion temperatures must be matched so that no layer tries to dominate the interface. The table below shows the typical wall split and the temperature window in which the layers stay balanced. Getting this wrong is the root cause of most delamination and layer-thickness faults covered later.
| Layer | 機能 | Typical wall share | Co-extrusion temperature window | Key control point |
|---|---|---|---|---|
| Inner (functional) | Anti-scaling, smooth bore, optional PP-RCT | 20 to 25 percent | 200 to 225 degrees Celsius | Keep Ra low and layer centered on bore |
| Middle (structure) | Glass-fiber reinforced PP-R or EVOH barrier | 50 to 60 percent | 210 to 235 degrees Celsius (GF higher) | Carry hoop stress and expansion control |
| Outer (protection) | UV, abrasion, color identification | 20 to 25 percent | 195 to 220 degrees Celsius | Uniform skin, no streak or sink |
| Tie layer (where needed) | Bond PP to EVOH or GF-PP | 1 to 3 percent overall | 205 to 225 degrees Celsius | Adequate thermal match to both sides |
The art of three-layer pipe is not in the chemistry alone but in holding the layer ratio and the interface temperature steady for thousands of running hours. The equipment is judged by its consistency, not by a single good sample.
3. 材料システム and Standards for Three-Layer PPR Pipe
The composite pipe is only as good as the five materials that make up its layers and tie layers, and each material carries a specification that the raw-material system and the extrusion window must respect. The table below lists the core materials, their defining properties, and the roles they play. All values are typical engineering figures for pipe-grade compounds and should be confirmed against the specific compound certificate at procurement.
| 材料 | Defining property | Role in the composite pipe | Notes for the extrusion line |
|---|---|---|---|
| PP-R (Type 3 random copolymer) | 溶融流動率 0.25 to 0.5 gram per 10 minutes at 230 degrees Celsius and 2.16 kilogram | Base polymer for inner and outer layers | Stable barrel window 190 to 230 degrees Celsius |
| PP-RCT (beta-crystal nucleated) | Minimum required strength raised to 11.2 megapascal | High-temperature inner layer option | Needs controlled cooling to develop beta crystals |
| PP-R GF (glass-fiber reinforced) | 10 to 20 percent glass fiber, lower expansion coefficient | Middle reinforcement layer | Abrasive; wear-resistant barrel and screw needed |
| EVOH (ethylene vinyl alcohol copolymer) | Ethylene content 32 to 44 mole percent, strong oxygen barrier | Middle barrier layer for heating circuits | Hygroscopic; requires dried feed and tie layer |
| Tie layer (PP-g-MAH) | Maleic anhydride grafted polypropylene | Bonds PP to EVOH or glass-fiber PP | Thin layer, tight temperature match |
3.1 Standards that govern the pipe
The finished pipe is judged against a stack of product and hygiene standards that the production line must be capable of satisfying. These are referenced as plain text only: ISO 15874 defines the PP piping system for hot and cold water installations; EN ISO 9080 governs the long-term hydrostatic strength extrapolation that sets the service life basis; DIN 8077 and DIN 8078 specify dimensions and the general quality requirements for PP pipes; GB/T 18742 is the Chinese national standard family for PP-R piping; ASTM F2389 covers PP pressure pipe for plumbing; NSF/ANSI 61 and NSF/ANSI 61-G certify the material for contact with drinking water; and EU 10/2011 regulates plastic food-contact materials, which for potable water means the additive package must stay within migration limits. The extrusion equipment does not itself certify the pipe, but it must be able to hold the dimensional and property consistency those standards demand.
3.2 SDR series and the pressure-temperature relationship
The standard dimension ratio, SDR, is the ratio of outside diameter to wall thickness and it sets the pressure class. For a given material the lower the SDR the thicker the wall and the higher the pressure rating. The table below shows common SDR values for PP-R composite pipe and the indicative pressure class at representative service temperatures. Pressure ratings decline with temperature because the polymer creeps faster when warm, which is exactly why the high-rise hot water duty must be read at 60 to 70 degrees Celsius, not at the 20-degree-Celsius catalog value.
| SDR | Wall thickness ratio | Indicative PN at 20 degrees Celsius | Indicative PN at 60 degrees Celsius | Indicative PN at 70 degrees Celsius | Indicative PN at 80 degrees Celsius |
|---|---|---|---|---|---|
| SDR 6 | Thick wall | PN 20 | PN 10 to 12 | PN 8 to 10 | PN 6 to 8 |
| SDR 7.4 | Thick wall | PN 16 | PN 8 to 10 | PN 6 to 8 | PN 5 to 6 |
| SDR 9 | Medium wall | PN 12.5 | PN 6 to 8 | PN 5 to 6 | PN 4 |
| SDR11 | Medium-thin wall | PN 10 | PN 5 to 6 | PN 4 | PN 3.2 |
上記の圧力値は、計画のための参考値であり、ISO 15874による特定の化合物の長期強度から計算された設計応力の代わりにはなりません。これらは、重要な点を示しています: 常温でPN 20のパイプは、連続70℃の熱水でPN 8にしかならない可能性があり、中間層がボアを制限する壁を太くすることなく余裕を取り戻せるのは、複合構造によるものです。
4. 三層共押出ライン: メイン押出機と共押出機
生産ラインの中心はエクストラクショングループです。大量の中間層溶融物を供給するメインエクストラーダに加えて、2つの共同エクストラーダがあり、薄い内部と外部の皮を形成します。層の容量が1桁で異なるため、機械はそれに応じてサイズ調整されます。メインエクストラーダは、直径45から90ミリメートル、L/D比30から33、およびPP固有のバリアスクリューを備えた大型の単一スクリュー装置です。スループットは、最小のメインマシンで約120キログラム/時間から最大のもので約800キログラム/時間まで拡張し、直径の範囲は20から160ミリメートルです。バレルは、温度プロファイルをPP-R、PP-RCT、または高温のガラス繊維コンパウンドに合わせて調整できるように、独立して制御されたゾーンで加熱されています。ガラス繊維の中間層の場合、バレルとスクリューのフライト面は、耐摩耗性処理を使用しており、ガラス繊維が研磨性があるため、シーズン中に計量セクションを摩耗させないようにします。
4.1 メイン押出機: シングルスクリュー、バリアスクリュー
主なエクストラーダでは、直径45～90ミリメートルのL/D比30～33の単一ねじとPP専用のバリアねじを使用しています。バリア部は溶融ポリマーと固体ポリマーを分離し、ダイに供給される溶融物が均一で完全にプラスチケーションされていることを保証します。これは、ガラス繊維や鉱物が混入された中間層が、未溶解の凝集体を含まないようにするために非常に重要です。スループットはねじ径と比例し、最小の主機では約120キログラム/時間、最大の機では約800キログラム/時間となり、直径は20～160ミリメートルの範囲をカバーします。バレルは独立して制御されるゾーンで加熱され、PP-R、PP-RCT、または高温のガラス繊維コンパウンドに合わせて温度プロファイルを調整できます。ガラス繊維中間層の場合、バレルとねじフライト面は耐摩耗処理を施しています。ガラス繊維は研磨性があるため、シーズン内に計量部が摩耗してしまいます。
4.2 機能皮膜用の2つの共押出機
内部防スケア層と外部保護層はそれぞれ、直径30から50ミリメートルの専用共同エクストラーダによって供給されます。これらの機械は低出力で動作しますが、安定性が高く、スキンスループットが1パーセント変化すると、層の比率が変わり、滑らかな内部表面が中心からずれる可能性があります。これらの共同エクストラーダは、精密な温度制御を備え、一部は熱に敏感な抗菌添加物を含む薄い機能性コンパウンドを使用します。中間層がEVOHの場合、これらの共同エクストラーダの1つは代わりにタイ層またはバリアー自体を供給し、ダイはそれに応じて層を分配します。
4.3 機器仕様表
以下の表は、代表的な3層ラインの押出グループをまとめています。直径範囲や層の選択によって、正確な値は変化しますが、ファイゴファミリー全体ではアーキテクチャは変わりません。
| Machine | Screw diameter | L/D ratio | Screw type | Throughput | Main duty |
|---|---|---|---|---|---|
| Main extruder | 45 to 90 millimeter | 30 to 33 | PP barrier screw | 120 to 800 kg/h | Middle structural layer |
| Co-extruder 1 | 30 to 50 millimeter | 28 to 33 | Barrier screw | 10 to 60 kg/h | Inner anti-scaling layer |
| Co-extruder 2 | 30 to 50 millimeter | 28 to 33 | Barrier screw | 10 to 80 kg/h | Outer protection or tie layer |
| Melt pump (optional) | Matched to output | n/a | Gear pump | Stabilizes pressure | Layer uniformity |
4.4 Common debugging points for the extrusion group
When the layers drift, the cause is almost always in this group. A wandering inner-layer percentage usually traces to co-extruder screw speed instability or a feed starvation in the small hopper, which is why gravimetric or loss-in-weight feeding is preferred over volumetric for the skin lines. A lumpy middle layer points to insufficient plasticizing in the main barrel, corrected by raising the rear or middle zone a few degrees or by checking the barrier flight clearance. Glass-fiber streaking in the middle layer signals fiber agglomeration and calls for a review of the concentrate letdown and the screw shear. Stabilizing the extrusion group is the first task at every commissioning because every downstream station assumes a steady, well-melted feed.
5. スパイラルマンドレル共押出金型と真空校正
パイプを作る金型は、3つの独立した溶融物を1つのパイプにする場所です。これはライン上で最も寛容な部品であり、各層の流れの不一致は、金型地面に永続的に表れます。このパイプ用の3層共押出金型は、スパイラルマンドレル金型であり、スパイラル配分が最も均一な周囲の層厚を提供するため、選ばれました。3層では、金型は共にマンドレルを囲む回転軸の周りに3つの配分システムを積み重ね、それぞれの押出機から供給されます。設計目標は、周囲で±5パーセントの層厚の均一性であり、小さいサイズのボアはスケール防止の余裕を失い、中間層が周囲で小さいサイズの場合は圧力評価を失います。溶融物の流れのチャネルは、界面が平らで波打つことがないように形成されています。界面の波打ちは、薄い層が繰り返し変化し、最終的にパイプを通して破れる古典的な故障です。金型体の温度は厳密に保たれ、金型地面の温度のわずかな変化で、局所的な粘度が変化し、層のジオメトリーが歪みます。
5.1 スパイラルマンドレル型の層の均一性
スパイラルマンドレル型の型は、各溶融体をマンドレルの周りを回る螺旋状のチャネルを通して供給し、流れを徐々に合体させることで、層が型地に到達する際に、分離した供給点ではなく、均一な円環状シートとして到達するようにします。3層の場合、型は共通のマンドレルの周りに3つの分布システムを積み重ね、それぞれが自分のエクストラーダから供給されます。設計目標は、周囲で±5％の範囲内の層厚の均一性です。これは、一端の穴が薄くなると防スケール性能を失い、また、中間層の一端が薄くなると圧力評価を失うという問題を引き起こすためです。溶融流路は、界面が平らで波打たないように形状づけられており、界面の波動は、パイプ全体に繰り返し現れ、最終的に破損する典型的な故障です。型体の温度は厳密に管理され、型地の一部で数度の温度変化が生じると、局所的な粘度が変化し、層の形状が歪みます。
5.2 真空校正タンク
ダイの直後、パイプはサイジングスリーブへ吸引され、ポリマーが硬化する前に外径と円周度が決められます。サイジングスリーブの材料は摩擦が小さく、高い熱利用性があるもので、多くの場合は処理したアルミニウムか、スリーブ鋼となります。その孔径はパイプの基準寸法です。周囲の真空は-0.02~-0.06メガパスカルの範囲で設定され、パイプをスリーブに堅く留める適切な圧力を生み出します（圧縮されない）。真空槽内の水の温度は12～18℃に保たれ、外磁器が迅速に硬化するとともに、芯の製造可能性を維持するのに十分な時間があります。サイジングが、円面度と外径が定まったところです。真空槽の長さ、水温、真空度がそれぞれの管径とライン速度に合わせて調整されます。
5.3 校正と冷却パラメータ表
| パラメータ | 一般的設定 | Effect if wrong |
|---|---|---|
| Calibration vacuum | minus 0.02 to minus 0.06 MPa | Too low: ovality; too high: collapse or sink |
| 調整水 temperature | 12 to 18 degrees Celsius | Too warm: poor set, large shrinkage |
| Sizing sleeve finish | Low-friction, polished bore | Rough sleeve scores the outer skin |
| First tank length | Matched to diameter and speed | Short tank: incomplete set before haul-off |
5.4 Debugging the die and calibration
The most common die fault is circumferential layer variation, corrected by balancing the spiral channel feeds and confirming that all three extruders deliver steady pressure. Interface waviness is fought by narrowing the temperature gap between adjacent layers and by slowing the line slightly so the melt relaxes before freezing. Ovality that calibration cannot remove usually means the vacuum is uneven around the sleeve or the pipe is pulled off-center; checking the centering of the die to the tank and the vacuum porting resolves most cases. Because the die and calibration together define the pipe shape, they are commissioned together and only then handed to the cooling and pull stations.
6. 下流: 冷却、ハウルオフ、惑星型カッター、およびオンライン検査
Once the pipe leaves calibration it must be cooled through its full wall, pulled at a perfectly steady speed, cut without burr, stacked, and measured continuously. The downstream group looks simple but it is where line-speed stability and final dimensional quality are decided.
6.1 Spray cooling tank
After the calibration tank the pipe passes through a spray cooling tank, usually built in multiple stages so that cooling is gradual rather than shock. Gradual cooling matters for the composite pipe because the glass-fiber middle layer and the PP skins cool and shrink at different rates; too fast a quench locks in internal stress that later shows up as warpage or, worse, as a hidden delamination driver. The outlet wall temperature is held below 40 degrees Celsius before the pipe reaches the haul-off, because a warm pipe stretches under pull and loses diameter control. Multi-stage spray also lets the line run faster for a given tank length, which is how the larger-diameter configurations reach their higher throughput.
6.2 Haul-off with synchronized belts
The haul-off grips the pipe between belts and pulls it at the speed that sets the final wall thickness through the draw-down ratio. For composite pipe the haul-off uses double or triple belts so the grip is distributed and the thin outer skin is not crushed, and the traction force and line speed are held in synchronization to within plus or minus 0.5 percent. A drift in pull speed is the fastest way to make the wall thickness wander, because every percent of speed change is a percent of wall thickness change at the die. Belt pressure is tuned so the pipe is held without marking, and the drive is a closed-loop servo system referenced to an encoder on the belt.
6.3 Planetary cutter and collection
The planetary cutter travels with the pipe while cutting, so the cut is made without stopping the line and without burr. A rotating ring of blades orbits the pipe at the line speed, giving a square, clean cut face. Cut squareness matters because the pipe ends must be fusion-welded, and a skewed end makes a weak joint. After cutting, the length drops onto a tipping rack or is conveyed to a collection station where it is stacked for transfer to the test and packaging area. Because the composite pipe is heavier per meter than a single-layer wall of the same diameter, the collection system is sized for the actual finished weight, not for a light reference pipe.
6.4 Online inspection
Modern lines carry continuous inspection rather than batch sampling alone. Ultrasonic thickness gauges scan the wall and can report each layer’s thickness if the layers have distinct acoustic properties, laser gauges measure the outside diameter with micrometer accuracy, and cameras or probes sample the inner wall smoothness to confirm the anti-scaling finish. A hydrostatic test bench sits at the end of the line or in the test bay to confirm pressure rating on a representative sample. The inspection data feeds a closed-loop wall-thickness control that nudges the haul-off speed or extruder outputs to hold the target wall, so the pipe stays in tolerance across the whole production run rather than only at the start.
| Downstream station | Key parameter | Accepted tolerance |
|---|---|---|
| Spray cooling | Outlet wall temperature | below 40 degrees Celsius |
| Haul-off | 速度とトラクションの同期 | within plus or minus 0.5 percent |
| Planetary cutter | Cut face squareness | perpendicular within 1 degree |
| Online gauge | Outside diameter and wall | continuous, closed-loop corrected |
7. Process Parameter Tables for Three-Layer Co-Extrusion
プロセスウィンドウは、すべての3層を正しい比率で保ち、パイプを正しい寸法に保つための温度、圧力、および速度のセットです。以下の表は、試運転および生産の切り替え時に使用される参考値です。これらは、工学上の値であり、選択された化合物に基づいて各ラインで最終決定されます。
7.1 Barrel and die temperature profile
The main PP-R layer runs about 190 to 230 degrees Celsius across the barrel zones, with the glass-fiber middle layer run somewhat higher to keep the filled compound fluid, and the EVOH or tie layer held in its own narrow band to protect its barrier properties. The die body sits at the top of the range so the melts stay uniform as they distribute. Too cold and the layers fail to fuse; too hot and the additives degrade and the interface smears.
| Zone | PP-R inner / outer | Glass-fiber middle | EVOH / tie middle |
|---|---|---|---|
| Feed zone | 190 to 200 degrees Celsius | 195 to 210 degrees Celsius | 195 to 205 degrees Celsius |
| Compression zone | 205 to 215 degrees Celsius | 210 to 225 degrees Celsius | 205 to 215 degrees Celsius |
| Metering zone | 210 to 225 degrees Celsius | 220 to 235 degrees Celsius | 210 to 220 degrees Celsius |
| Die body | 215～230度摂氏温度 | 220 to 235 degrees Celsius | 215 to 225 degrees Celsius |
7.2 溶融圧力, vacuum, cooling and speed matching
溶融圧力 at the die is held at 15 to 30 megapascal so the layers are pressed into intimate contact and the spiral distribution stays full. Vacuum, water temperature and line speed are matched to diameter as shown, and the wall thickness is held by a closed loop that links haul-off speed to the measured wall. The smaller diameters run fast; the larger diameters run slow because the wall mass per meter is far greater.
| Nominal diameter | 溶融圧力 | Calibration vacuum | Cooling water | ライン速度 | Throughput |
|---|---|---|---|---|---|
| 20 millimeter | 15 to 22 MPa | minus 0.02 to 0.04 MPa | 12 to 18 degrees Celsius | 12 to 22 m/min | 120 to 180 kg/h |
| 32 millimeter | 16 to 24 MPa | minus 0.02 to 0.05 MPa | 12 to 18 degrees Celsius | 8 to 16 m/min | 150 to 240 kg/h |
| 63 millimeter | 18 to 26 MPa | minus 0.03 to 0.05 MPa | 12 to 18 degrees Celsius | 4 to 9 m/min | 180 to 320 kg/h |
| 110 millimeter | 20 to 28 MPa | minus 0.04 to 0.06 MPa | 12 to 18 degrees Celsius | 2 to 5 m/min | 300 to 600 kg/h |
| 160 millimeter | 22 to 30 MPa | minus 0.04 to 0.06 MPa | 12 to 18 degrees Celsius | 1.5 to 3.5 m/min | 380 to 800 kg/h |
7.3 Wall thickness closed-loop control
The wall is not set once and forgotten. The online gauge reports outside diameter and wall, the control system compares them to the target for the selected SDR, and it trims the haul-off speed and the extruder outputs to remove drift. This closed loop is what lets a line hold tolerance across a full shift instead of only on the first spool. It also protects the expensive inner compound, because if the inner layer starts to wander thin the loop can compensate before the anti-scaling margin is lost.
8. Verifying and Quantifying Anti-Scaling Performance
The anti-scaling claim is only credible if it is measured the same way every time and reported against a reference pipe. The test method and the comparison frame below are the ones used to quantify the inner-layer performance and to express the improvement as a relative multiple rather than an absolute promise.
8.1 Scaling test method
The pipe sample is mounted in a loop through which hard water circulates at a calcium carbonate concentration of 300 to 500 milligram per liter, held at about 60 degrees Celsius, and run for 500 to 2000 hours. At the end the scale layer thickness and the mass increment per unit area are measured, the inner wall roughness is re-measured to see how much the bore has roughened, and the flow decay rate is calculated from the pressure drop at constant flow. A separate antibacterial check uses the ISO 22196 method, which counts bacterial reduction on the surface against a control. The whole battery is repeated on a reference single-layer PPR pipe of the same diameter and SDR so the comparison is fair.
8.2 Comparison against ordinary PPR
Because the inner surface of the composite pipe is smoother and lower energy, calcium carbonate nucleates far less readily, and the result is a much slower scale build-up. The table expresses the improvement as a relative multiple of the scaling rate of ordinary PPR, which is the honest way to state the benefit without implying a fixed lifetime number that depends on local water chemistry.
| Metric | Ordinary PPR (reference) | Composite anti-scaling PPR | Improvement |
|---|---|---|---|
| Inner wall roughness Ra | 0.8 to 1.5 micrometer | not more than 0.3 micrometer | smoother bore |
| Scale mass increment | Reference value | lower multiple of reference | >スケーリング率が数倍に減少した |
| Flow decay after test | Reference value | lower multiple of reference | flow retained longer |
| Antibacterial activity | none | reduced count per ISO 22196 | biofilm suppressed |
精密な乗数は、水の硬度、温度および流動速度によって異なるため、設備と材料は、そのデータが存在する場合はお客様の実際の水に基づいて検証されます。ストレートラインが保証するものは、低いスケール率を可能にする表面品質です：各パイプの全長においてスムーズで中央に位置する穴です。
9. System Design Support for High-Rise 用途
Making the pipe is only half the job; the pipe must be installed so that its properties are used correctly. The composite PPR pipe changes several design rules compared with a single-layer wall, and the equipment supplier should be able to advise on these so the finished building performs.
9.1 Zoned supply and pressure reduction
Because the base of a tall building sees 1.0 to 1.2 megapascal, the distribution is split into pressure zones, each served by its own riser and each protected by pressure-reducing valves so that no branch sees more than its rated pressure. The pipe grade and SDR are chosen per zone: lower zones use thicker SDR or PP-RCT inner layers, upper zones can use thinner walls. The co-extrusion line’s ability to hold SDR tightly is what makes this zoned design safe, because a wall that wanders thin would break the zone calculation.
9.2 Hot water circulation return
To avoid drawing cold water at every distant tap, high-rise systems use a circulation loop with a return pipe so water is always moving and always warm. Moving water scales more slowly than stagnant water, which complements the anti-scaling bore. The return loop also limits the time the pipe spends at peak temperature, extending the effective life. The pipe’s fusion joints must be planned so the loop can be balanced, and the composite pipe’s consistent wall makes joint heating predictable.
9.3 Thermal expansion compensation
Even with the glass-fiber middle layer cutting expansion to 0.03 to 0.05 millimeter per meter per Kelvin, a long vertical riser still moves with temperature, and that movement must be absorbed by expansion joints and anchored by fixed supports at planned intervals. The table gives indicative fixed-support spacing for the glass-fiber composite riser; the plain PPR value would be much shorter and would require far more anchors. Proper spacing prevents the pipe from buckling in its chase and prevents the joints from being loaded in bending.
| Diameter | Fixed support spacing (GF composite) | 補償方法 |
|---|---|---|
| 20 to 25 millimeter | about 2.5 to 3.0 meter | Expansion joint at riser base |
| 32 to 40 millimeter | about 3.0 to 3.5 meter | Joint plus guide supports |
| 50 to 63 millimeter | about 3.5 to 4.0 meter | Joint plus guide supports |
| 75 to 110 millimeter | about 4.0 to 5.0 meter | Larger joint, fewer anchors |
9.4 Insulation and fusion joint parameters
The riser is insulated to hold the service temperature and to protect any exposed portions from ultraviolet. Joints are made by hot-melt fusion, with a melt temperature of 260 plus or minus 10 degrees Celsius and heating and cooling times scaled to diameter. The table below gives the indicative heating and cooling times; these are planning values and the jointing tool’s own schedule should be followed on site. Consistent wall from the extrusion line makes these times reliable, because the heater encounters the same wall thickness at every joint.
| Diameter | Heating time | Cooling time | 溶融温度 |
|---|---|---|---|
| 20 millimeter | about 5 seconds | about 2 minutes | 260 plus or minus 10 degrees Celsius |
| 32 millimeter | about 8 seconds | about 4 minutes | 260 plus or minus 10 degrees Celsius |
| 63 millimeter | about 18 seconds | about 7 minutes | 260 plus or minus 10 degrees Celsius |
| 110 millimeter | about 35 seconds | about 12 minutes | 260 plus or minus 10 degrees Celsius |
10. Faygo Three-Layer PPR Co-Extrusion 生産ラインs
Faygo offers the three-layer composite PPR capability as configurations of its PP-R/PE-RT パイプ押出ライン, the same product family that covers PP-R and PE-RT pipes from 16 to 160 millimeter. Two configurations cover the diameter bands most relevant to high-rise domestic hot water, and both are built on the extrusion group, spiral mandrel co-extrusion die, vacuum calibration, spray cooling, synchronized haul-off, planetary cutter and online inspection described above. The specifications below are representative; final values are confirmed against the chosen layer structure and compound.
10.1 Configuration A: small-to-medium diameter 20 to 63 millimeter
This configuration targets the branch and riser diameters most common inside apartments and on the upper floors of a building. It pairs a mid-size main extruder with two skin co-extruders and a three-layer spiral mandrel die. The line is compact enough for a modest floor area yet covers the full range of apartment hot water piping. The smooth inner layer is produced from a dedicated hopper so the anti-scaling compound is never contaminated by the structural middle layer.
| 仕様書 | Configuration A (20 to 63 millimeter) |
|---|---|
| パイプの口径の範囲 | 20 to 63 millimeter |
| Main extruder | Single-screw 60 millimeter, L/D 33, PP barrier screw |
| Co-extruder 1 (inner) | Single-screw 30 millimeter, L/D 30 |
| Co-extruder 2 (outer or tie) | Single-screw 45 millimeter, L/D 30 |
| Throughput | 120 to 260 kilogram per hour |
| ライン速度 | 4 to 22 meter per minute (by diameter) |
| インストール電力 | about 145 kilowatt |
| Line length | about 28 meter |
| Co-extrusion layers | 3 (inner functional, middle GF or EVOH, outer) |
| Calibration method | Vacuum calibration sleeve, water 12 to 18 degrees Celsius |
10.2 Configuration B: large diameter 75 to 160 millimeter
This configuration serves the main risers and plant-room headers where wall mass and throughput are highest. It uses the largest main extruder in the family and the full three-layer die, and it is the line chosen when a project needs both the glass-fiber expansion control and the anti-scaling bore in one product at volume. The higher installed power and longer line reflect the greater cooling and pull load of the heavy large-diameter pipe.
| 仕様書 | Configuration B (75 to 160 millimeter) |
|---|---|
| パイプの口径の範囲 | 75 to 160 millimeter |
| Main extruder | Single-screw 90 millimeter, L/D 33, PP barrier screw |
| Co-extruder 1 (inner) | Single-screw 40 millimeter, L/D 30 |
| Co-extruder 2 (outer or tie) | Single-screw 50 millimeter, L/D 30 |
| Throughput | 320 to 800 kilogram per hour |
| ライン速度 | 1.5 to 10 meter per minute (by diameter) |
| インストール電力 | about 280 kilowatt |
| Line length | about 36 meter |
| Co-extrusion layers | 3 (inner functional, middle GF or EVOH, outer) |
| Calibration method | Vacuum calibration sleeve, water 12 to 18 degrees Celsius |
Both configurations share the Faygo intelligent control system, which lets operators set parameters freely and adjust in real time, and both use internationally recognized brand electrical components for reliability. They leave the plant after the standard seventy-two-hour continuous operation test, which is where the layer consistency and the closed-loop wall control are proven before shipment.
11. Requirement-to-Model Selection Guide
The right configuration follows directly from the project’s diameter range, the required layer structure and the target output. The table below maps common high-rise hot water requirements to the Faygo PP-R/PE-RT パイプ押出ライン configuration that satisfies them. Where the duty is a closed heating circuit rather than potable hot water, the EVOH barrier middle layer is selected instead of glass fiber.
| 直径の範囲 | Layer structure | Target output | Recommended Faygo configuration |
|---|---|---|---|
| 20 to 32 millimeter | 2-layer anti-scaling (inner functional plus outer) | 120 to 180 kg/h | PP-R/PE-RT line, Configuration A, 2-layer mode |
| 20 to 63 millimeter | 3-layer with glass-fiber middle | 180 to 260 kg/h | PP-R/PE-RT line, Configuration A, 3-layer mode |
| 20 to 63 millimeter | 3-layer with EVOH barrier middle | 180 to 260 kg/h | PP-R/PE-RT line, Configuration A, EVOH mode |
| 75 to 110 millimeter | 3-layer composite, GF or EVOH | 320 to 600 kg/h | PP-R/PE-RT line, Configuration B |
| 110 to 160 millimeter | 3-layer composite, GF middle | 500 to 800 kg/h | PP-R/PE-RT line, Configuration B, high-output |
| 20 to 110 millimeter | 3-layer with PP-RCT inner, high temp | 180 to 600 kg/h | PP-R/PE-RT line, Configuration A or B with PP-RCT option |
For projects that also need other pipe families, the Wanplas group can supply adjacent extrusion lines so a single supplier covers the whole building services package, but on the faygo-china.com scope the recommendation stays within the Faygo pipe and profile extrusion product range.
12. Common Defects and Countermeasure Matrix
Even a well-designed line develops faults, and the composite structure has a few failure modes that single-layer pipe does not. The matrix below is the field reference used during commissioning and routine production. Each fault lists the likely cause and the corrective action, ordered so the operator can move from symptom to fix without guesswork.
| 瑕疵 | Likely cause | Countermeasure |
|---|---|---|
| Layer thickness uneven | Co-extruder speed drift, unbalanced spiral feed | Stabilize skin extruder with gravimetric feed; rebalance die channels |
| Inner layer delamination | Tie layer insufficient or temperature mismatch | Increase tie layer; narrow temperature gap between layers |
| Inner wall scratches | 校正スリーブ damage, foreign particles | Polish or replace sleeve; filter melt and clean feed |
| Outside diameter fluctuation | ハウルオフスピード drift, vacuum unstable | Recalibrate servo sync; check vacuum porting |
| Ovality over limit | Off-center die to tank, uneven vacuum | Center die; balance vacuum around sleeve |
| Inner shark skin | Inner melt too cold or too fast at die land | Raise inner layer die temperature slightly; reduce speed |
| Bubbles and water marks | Moisture in feed, especially EVOH | Dry EVOH and hygroscopic compounds; check hopper |
| Cut burr | Dull cutter blade, wrong tracking speed | Sharpen or replace blade; match cutter to line speed |
| Hydrostatic test failure | Wall below target, weak fusion, voids | Enforce closed-loop wall control; review joint quality |
Most of these faults trace back to the same two themes: unstable extruder metering and poor temperature matching at the interface. The Faygo line’s gravimetric feeding on the skin extruders and its tight die temperature control are the design features that prevent the majority of them before they start.
13. サービスとサポート From Faygo
A production line is a long-term asset, and the value of the supplier is measured over the years after commissioning as much as at the moment of purchase. Faygo, as a Wanplas factory, delivers the group’s shared service承诺 through a defined support program that begins before shipment and continues through the full operating life of the line.
13.1 Testing and commissioning
Every line is run for seventy-two hours of continuous operation at the factory before it is approved for shipment, so that layer consistency, wall control and line speed are proven under load rather than on paper. After arrival, Faygo engineers assist with installation and commissioning, bring the line to rated output, and run a trial production and sampling batch so the customer sees finished pipe before acceptance. The trial batch is also the moment to validate the anti-scaling bore finish and the hydrostatic sample against the project specification.
13.2 Spare parts, training and remote operation
The Wanplas group policy provides USD 500 free spare parts per year for the line, with warranty replacement for damaged parts inside the warranty period. Operators receive hands-on training in setup, changeover and routine maintenance, and the intelligent control system supports remote monitoring so Faygo engineers can read process data and help resolve faults without delay. Because the control platform stores recipes, a diameter or layer change can be repeated reliably once it has been tuned.
13.3 オープン工場 and project services
Faygo welcomes customer visits to its Zhangjiagang plant, where the 26,650 square metre facility, the three specialized factories and the running lines can be inspected directly. Beyond the machine itself, Faygo offers factory consulting covering water and electricity design, three-dimensional workshop layout, worker configuration and training, and new-factory or capacity-expansion projects. For customers who need a complete building-services pipe package, the Wanplas group can coordinate adjacent extrusion lines so the whole scope is sourced and supported under one engineering responsibility.
よくある質問
Why use a three-layer composite structure instead of a single-layer PPR pipe for high-rise hot water?
単層の PPR パイプは圧力と温度に対応できますが、スケーリング、酸素浸透、線形膨張、および表面汚染を同時に制御できません。三層の複合材料では、各機能が分離されています。内側の防スケーリング機能層はボアを滑らかに保ち、中間のガラス繊維または EVOH 層は膨張または酸素透過性を制御し、外側の保護層は紫外線と機械的損傷に耐えます。この分離により、各層が互いに妥協せずに最適化できます。
What is the difference between a glass-fiber middle layer and an EVOH middle layer?
Glass-fiber reinforced PP-R lowers the linear expansion coefficient from about 0.15 to 0.03 to 0.05 millimeter per meter per Kelvin, which stabilizes long vertical risers and reduces the number of fixed supports. EVOH (ethylene vinyl alcohol copolymer) is an oxygen barrier used in closed heating circuits to stop oxygen diffusing through the wall and corroding metal pumps and valves, keeping oxygen permeability below 0.1 gram per cubic meter per day per DIN 4726. Many domestic hot water lines choose the glass-fiber version; heating systems choose EVOH.
How is anti-scaling performance of the inner layer verified?
The standard approach circulates hard water with 300 to 500 milligram per liter calcium carbonate at about 60 degrees Celsius for 500 to 2000 hours, then measures scale layer thickness, mass increment, inner wall roughness and flow decay. Antibacterial function is checked by the ISO 22196 method. The result is compared against a reference single-layer PPR pipe to express scaling rate reduction as a relative multiple rather than an absolute figure.
What extruder configuration does a three-layer PPR co-extrusion line use?
The line uses one main 単一スクリュエキストラクター, typically diameter 45 to 90 millimeter with L/D 30 to 33 and a PP barrier screw, plus two co-extruders of 30 to 50 millimeter for the inner functional layer and the middle or outer layer. A spiral mandrel co-extrusion die combines the three melts into a pipe with layer uniformity within plus or minus 5 percent.
Which Faygo production line fits a given diameter and layer structure?
For 20 to 63 millimeter three-layer PPR the Faygo PP-R/PE-RT パイプ押出ライン in the small-to-medium diameter configuration covers 120 to 260 kilogram per hour. For 75 to 160 millimeter three-layer composite pipe the large-diameter configuration covers 320 to 800 kilogram per hour. Both are configurations of the same Faygo PP-R/PE-RT パイプ押出ライン product family and share vacuum calibration, planetary cutting and online inspection.
What melt temperature and calibration conditions are typical for three-layer PPR?
The PP-R base layers run about 190 to 230 degrees Celsius in the barrel zones, with the glass-fiber or EVOH layer run somewhat higher to match viscosity. 溶融圧力 at the die is 15 to 30 megapascal, vacuum calibration is set at minus 0.02 to minus 0.06 megapascal with cooling water at 12 to 18 degrees Celsius, and the outlet wall temperature from the spray tank stays below 40 degrees Celsius before the haul-off.
How does Faygo support installation and after-sales for a complete line?
Every line is run for 72 hours of continuous operation testing before delivery, then engineers assist with installation and commissioning, trial production and sampling. The Wanplas group policy provides USD 500 free spare parts per year plus warranty replacement, 24/7 online technical support, operator training and an open factory welcome for customer visits and audits.
結論
100メートルの建物の給湯システムは、低層のネットワークよりもパイプに多くの要求をかけます。基部では耐圧性、上部では耐温性、50年間スケールを拒否する穴、そして暖めると冷やすと曲がらない壁が必要です。3層の複合アンチスケーリングPPRパイプは、それぞれの役割を各層に割り当てることでこれらの4つすべてに対応します。これを実現するための押出設備は、安定した押出グループ、スパイラルマンドレルダイ、真空校正、安定したハウルオフ、および連続的な検査を備えたシンクロナイゼドコエクストルジョンシステムです。
Faygo, a Wanplas factory with twenty-two years of pipe and profile extrusion experience, builds this capability into its PP-R/PE-RT パイプ押出ライン in configurations covering 20 to 160 millimeter, with the layer structure, throughput and control needed for genuine high-rise duty. Every line is proven over seventy-two hours before shipment, supported by the Wanplas group’s USD 500 free spare parts per year policy, remote operation assistance and open-factory access.
If you are specifying equipment for a high-rise domestic hot water project, send us your diameter range, target output, layer structure and local water chemistry. Our engineering team will return a tailored line configuration, arrange a trial production and sampling at our Zhangjiagang plant, and walk you through commissioning and operator training so the pipe you make meets the building’s fifty-year expectation from the first meter to the last.
