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 equipment3~0.8mm이므로 핸들링 및 얕은 스크래치 처리 시에도 마킹이 유지됩니다.
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 파이프 압출 라인 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, Wanplas 공장 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 가정용 온수 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 50년 설계 수명
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.
네 가지 어려움이 한 벽면에 동시에 작용할 때, 가장 견고한 대응책은 기능을 여러 층으로 분리하는 것입니다. 이러한 분리 기능은 바로 삼층 동공성형 장비가 제공하는 것입니다.
2. Functional Layer Structure 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 0.3 마이크로미터 이하, 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
The outer layer is the pipe’s skin to the world. It carries ultraviolet stabilizer so the pipe survives site storage and temporary exposure before embedding, abrasion resistance so it is not scored during installation, and color or stripe identification so installers can distinguish the anti-scaling composite from ordinary PPR at a glance. It also provides a weathering-resistant surface for the portions of pipe that may be exposed in plant rooms. Because it is a thin skin, it can be tinted or striped without affecting the structural or hygienic layers, which is why the composite pipe is often visibly marked as a special product.
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 | 기능 | 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 장벽 | 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. Material System 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.
| 재료 | Defining property | Role in the composite pipe | Notes for the extrusion line |
|---|---|---|---|
| PP-R (Type 3 random copolymer) | Melt flow rate 0.25 to 0.5 gram per 10 minutes at 230 degrees Celsius and 2.16 kilogram | 내부 및 외부 층을 위한 기본 폴리머 | Stable barrel window 190 to 230 degrees Celsius |
| PP-RCT (beta-crystal nucleated) | 최소 요구 강도 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 압력 파이프 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 시리즈와 압력-온도 관계
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 | 벽 두께 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 |
| SDR 11 | Medium-thin wall | PN 10 | PN 5 to 6 | PN 4 | PN 3.2 |
위의 압력 수치는 계획용으로 참고할 수 있는 관계이며, ISO 15874에서 사용되는 특정 화합물의 장기적인 강도를 계산한 설계 응력 대신 사용할 수 없습니다. 이들은 중요한 점을 보여줍니다. 실온에서 PN 20인 파이프는 지속적으로 70도씨의 뜨거운 물에서 PN 8에 불과하며, 복합 구조는 중층이 구멍을 좁히는 벽을 두껍게 만들지 않고 여백을 회복할 수 있게 합니다.
4. 삼층 동형 압출 라인: 주 압출기 및 동형 압출기
The heart of the production line is the extrusion group: one main extruder that delivers the bulk middle-layer melt, plus two co-extruders that lay down the thin inner and outer skins. Because the layers differ in volume by an order of magnitude, the machines are sized accordingly. The main extruder is a large single-screw unit; the skin extruders are small, precise single-screw units whose job is layer placement rather than bulk output.
4.1 주 압출기: 단일 스크류와 장벽 스크류를 사용합니다.
주 압축기는 직경이 45 ~ 90mm, L/D 비율이 30 ~ 33인 한 개의 스크류를 사용하여 PP 저감 스크류를 사용합니다. 저감 섹션은 용융된 고체 폴리머를 분리해 배달되는 멘트가 균질하고 완전히 플라스틱화되었음을 보장하는데, 이는 강화 유리 섬유나 민감한 중층재가 포함된 다양한 수지의 경우 의의가 있습니다. 유동률은 공급기 직경에 따라 120kg/h ~ 800kg/h로, 20 ~ 160mm의 전체 직경 범위를 포함합니다. 배럴은 사전 설정 배열에 따라 독립적으로 제어되는 구역별로 가열되어 PP-R, PP-RCT 또는 더 높은 온도인 강화 유리 섬유 혼합물에 대한 온도 프로필을 조정할 수 있습니다. 강화 섬유 중층재의 경우 배럴과 스크류 기둥면은 마모가 강한 강화 유리 섬유로 인해 시간이 지나면 손상될 수 있으므로 초도비를 위해 내마모성이 뛰어난 처리 과정을 사용합니다.
4.2 기능성 피복용 두 개의 동시 압출기
The inner anti-scaling layer and the outer protective layer are each fed by a dedicated co-extruder of 30 to 50 millimeter diameter. These machines run at low output but must be metered with high stability because a one-percent drift in skin throughput changes the layer ratio and can shift the smooth inner surface off-center. They use the same barrier-screw philosophy in miniature, with precise temperature control so the thin functional compounds, some of which contain heat-sensitive antibacterial additives, are not degraded. When the middle layer is EVOH, one of these co-extruders may instead feed the tie layer or the barrier itself, and the die distributes the layers accordingly.
장비 사양표
아래 표는 대표적인 3층 라인용 압출 그룹을 요약한 것입니다. 정확한 값은 직경 범위와 층 선택에 따라 달라지지만, Faygo 제품군에서는 구조가 일관적입니다.
| Machine | 스크류 직경 | L/D 비율 | Screw type | Throughput | Main duty |
|---|---|---|---|---|---|
| 주 압출기 | 45 to 90 millimeter | 30 to 33 | PP 장벽 스크류 | 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. 스파이럴 맨들러 공동 압출 다이 및 진공 교정
다이(Die)는 세 개의 독립적인 용융물이 하나의 파이프로 합쳐지는 곳입니다. 파이프의 완성된 벽에 어떤 불일치도 영구적으로 나타나기 때문에 라인에서 가장 관대하지 않은 부품이 바로 다이입니다. 이 파이프용 3층 동시 압출 다이에는 나선형 맨드렐 다이(Spiral mandrel die)가 사용되었는데, 이는 나선형 분포가 다른 다이 형상 중 가장 균일한 원주면 층 두께를 제공하기 때문입니다.
5.1 나선형 맨드렐 다이와 층 균일성
비전 시스템은 지름 게이지가 볼 수 없는 결함을 튜브 표면에서 지속적으로 검사합니다.망설임 해결 방법을 탐지하는 일반적인 목표에는 검은 점과 50~100㎛까지의 겔, 표면 긁김 및 끌림 자국, 기포 및 벽이 없는 부분, 색상 및 불투명도 차이가 있으며, 줄무늬 경우 등등이 있습니다. 보통 다수의 각도에서 전 회절스고한장 빛을 조절하는 고속 선로 계측 카메라가 마지막 냉각 탱크 뒤 위치합니다. 탐지된 결함은 튜브의 위치와 함께 로그에 저장되고, 시스템에 따라 잉크젯 플래그로 표시되거나 해당 부분의 자동 우회를 지시합니다.
5.2 진공 교정 탱크
Immediately after the die the pipe enters the vacuum calibration tank, where it is pulled onto a sizing sleeve under vacuum so that the outside diameter and roundness are set before the wall freezes. The calibration sleeve material is chosen for low friction and good heat extraction, often a treated aluminum or a sleeved steel, and its bore is the master dimension for the pipe. Vacuum is set in the range of minus 0.02 to minus 0.06 megapascal, enough to hold the soft pipe against the sleeve without collapsing it. Cooling water in the tank is kept at 12 to 18 degrees Celsius so that the outer surface sets quickly while the core stays workable long enough to avoid internal stress. Calibration is where ovality and outside diameter are locked in, so the tank length, water temperature and vacuum level are tuned together for each diameter and line speed.
5.3 교정 및 냉각 parameter table
| 매개변수 | Typical setting | Effect if wrong |
|---|---|---|
| Calibration vacuum | minus 0.02 to minus 0.06 MPa | Too low: ovality; too high: collapse or sink |
| 교정 용수 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. 하류: 냉각, 운반, 행성 절단기 및 온라인 검사
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 스프레이 냉각 탱크
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 행성형 절단기 and collection
The 행성형 절단기 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 | 주요 파라미터 | Accepted tolerance |
|---|---|---|
| Spray cooling | Outlet wall temperature | below 40 degrees Celsius |
| Haul-off | Speed and traction sync | within plus or minus 0.5 percent |
| 행성형 절단기 | Cut face squareness | perpendicular within 1 degree |
| Online gauge | 외부 직경 and wall | continuous, closed-loop corrected |
7. 세 단계 코-압출 공정 매개변수 표
공정 창은 세 개의 층이 올바른 비율로 유지되고 파이프가 올바른 치수로 유지되는 온도, 압력 및 속도의 집합입니다. 아래 표는 시운전 및 생산 변경 시 사용되는 참조 기준입니다. 이는 선택된 화합물에 따라 최종적으로 각 라인에서 결정되는 참고 엔지니어링 값입니다.
7.1 Barrel and die temperature profile
주요 PP-R 층은 배럴 영역에서 약 190~230도씨로 흐르고, 유리 섬유 중층은 채워진 화합물이 유동하도록 유지하기 위해 약간 더 높은 온도에서 흐릅니다. EVOH 또는 결합층은 장벽 특성을 보호하기 위해 자체의 좁은 영역에서 유지됩니다. 다이 본체는 범위의 상단에 위치하여 용융물이 균일하게 분배됩니다. 너무 낮으면 층들이 융합되지 않고, 너무 높으면 첨가제가 저하되고 인터페이스가 흐려집니다.
| 구역 | PP-R inner / outer | 유리섬유 중간층 | EVOH / tie middle |
|---|---|---|---|
| Feed zone | 190 to 200 degrees Celsius | 195 to 210 degrees Celsius | 195~205도 |
| 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 to 230 degrees Celsius | 220 to 235 degrees Celsius | 215 to 225 degrees Celsius |
7.2 녹는 압력, vacuum, cooling and speed matching
녹는 압력 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 | 녹는 압력 | Calibration vacuum | Cooling water | 라인 속도 | 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 ~ 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 ~ 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 벽 두께 닫힌 루프 제어
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. 파이프 내 항스크레치 성능 확인 및 정량화
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 |
|---|---|---|---|
| 내부 벽 거칠기 Ra | 0.8 to 1.5 micrometer | 0.3 마이크로미터 이하 | smoother bore |
| Scale mass increment | 기준값 | lower multiple of reference | >스케일링 속도가 몇 배 감소했습니다. |
| 테스트 후 흐름 감쇠 | 기준값 | lower multiple of reference | 흐름이 더 오래 유지됨 |
| Antibacterial activity | none | reduced count per ISO 22196 | biofilm suppressed |
The precise multiple depends on water hardness, temperature and flow velocity, so the equipment and the material are validated against the customer’s actual water where that data is available. What the extrusion line guarantees is the surface quality that makes the lower scaling rate possible: a bore that stays smooth and centered for the full length of every pipe.
9. System Design Support for High-Rise 응용 분야
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) | Compensation method |
|---|---|---|
| 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 | 융해 온도 |
|---|---|---|---|
| 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 생산 라인s
Faygo offers the three-layer composite PPR capability as configurations of its PP-R/PE-RT 파이프 압출 라인, 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, 행성형 절단기 and online inspection described above. The specifications below are representative; final values are confirmed against the chosen layer structure and compound.
10.1 구성 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.
| 사양 | 구성 A (20~63 밀리미터) |
|---|---|
| 파이프 직경 범위 | 20 to 63 millimeter |
| 주 압출기 | Single-screw 60 millimeter, L/D 33, PP 장벽 스크류 |
| Co-extruder 1 (inner) | Single-screw 30 millimeter, L/D 30 |
| Co-extruder 2 (outer or tie) | 단일 스크류 45 밀리미터, L/D 30 |
| Throughput | 120 to 260 kilogram per hour |
| 라인 속도 | 4 to 22 meter per minute (by diameter) |
| 설치된 전력 | 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 구성 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.
| 사양 | 구성 B (75 to 160 millimeter) |
|---|---|
| 파이프 직경 범위 | 75 to 160 millimeter |
| 주 압출기 | Single-screw 90 millimeter, L/D 33, PP 장벽 스크류 |
| 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 |
| 라인 속도 | 1.5 to 10 meter per minute (by diameter) |
| 설치된 전력 | about 280 kilowatt |
| Line length | 약 36 미터 |
| Co-extrusion layers | 3 (inner functional, middle GF or EVOH, outer) |
| Calibration method | Vacuum calibration sleeve, water 12 to 18 degrees Celsius |
두 구성 모두 Faygo 지능형 제어 시스템을 사용하며, 이를 통해 운영자는 자유롭게 매개변수를 설정하고 실시간으로 조정할 수 있습니다. 또한 두 구성 모두 신뢰성을 위해 국제적으로 인정받은 브랜드의 전기 부품을 사용합니다. 표준 72시간 연속 가동 테스트를 통과한 후 공장을 떠나며, 이때 층의 일관성과 폐쇄 루프 벽 제어가 검증됩니다.
11. Requirement-to-Model 선택 가이드
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 파이프 압출 라인 configuration that satisfies them. Where the duty is a closed heating circuit rather than potable hot water, the EVOH 장벽 middle layer is selected instead of glass fiber.
| 직경 범위 | Layer structure | 목표 출력 | Faygo 구성 권장 사항 |
|---|---|---|---|
| 20 to 32 millimeter | 2층 방지 스케일링 (내부 기능 + 외부) | 120 ~ 180 kg / h | PP-R/PE-RT 라인, 구성 A, 2층 모드 |
| 20 to 63 millimeter | 3-layer with glass-fiber middle | 180 to 260 kg/h | PP-R/PE-RT line, 구성 A, 3-layer mode |
| 20 to 63 millimeter | 3-layer with EVOH 장벽 middle | 180 to 260 kg/h | PP-R/PE-RT line, 구성 A, EVOH mode |
| 75 to 110 millimeter | 3-layer composite, GF or EVOH | 320 to 600 kg/h | PP-R/PE-RT line, 구성 B |
| 110 to 160 millimeter | 3-layer composite, GF middle | 500 to 800 kg/h | PP-R/PE-RT line, 구성 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, 구성 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 방지 조치 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.
| 결함 | 유력한 원인 | 방지 조치 |
|---|---|---|
| Layer thickness uneven | Co-extruder speed drift, unbalanced spiral feed | Stabilize skin extruder with gravimetric feed; rebalance die channels |
| Inner layer delamination | 테이프 층이 부족하거나 층 간의 온도 차이가 크다 | 테이프 층을 늘리고 층 간의 온도 차를 좁힌다 |
| Inner wall scratches | 교정 슬리브 damage, foreign particles | Polish or replace sleeve; filter melt and clean feed |
| 외부 직경 fluctuation | 하우오프 속도 편차, vacuum unstable | Recalibrate servo sync; check vacuum porting |
| 난형도 초과 | 다이와 탱크가 오프센터에 위치해 있고 진공이 불균일하다 | 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 | 공급물에 수분이 많고, 특히 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. Faygo의 서비스 및 지원
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
모든 라인은 출하 승인을 받기 전에 공장에서 72시간 연속 가동 테스트를 거치므로 레이어 일관성, 벽 제어 및 라인 속도는 종이 상에서가 아니라 부하 상태에서 입증됩니다. 도착 후 Faygo 엔지니어는 설치 및 시운전을 지원하고 라인을 정격 출력으로 조정하며 고객이 완제품 파이프를 확인하기 전에 시험 생산 및 샘플 배치를 수행합니다. 시험 배치는 프로젝트 사양에 맞게 안티 스케일링 보어 마감과 수압 샘플을 검증하는 순간입니다.
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 Open factory 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.
자주 묻는 질문
Why use a three-layer composite structure instead of a single-layer PPR pipe for high-rise hot water?
단일층 PPR 파이프는 압력과 온도를 처리하지만, 스케일링, 산소 유입, 선형 팽창 및 표면 오염을 동시에 제어할 수 없습니다. 세 개의 층으로 구성된 복합재는 기능을 분리합니다: 내면의 스케일 방지 기능층은 보어를 부드럽게 유지하고, 중간의 유리 섬유 또는 EVOH 층은 팽창 또는 산소 투과성을 제어하며, 외부 보호층은 UV 및 기계적 손상을 방지합니다. 이러한 분할은 각 층을 타협하지 않고 최적화할 수 있게 합니다.
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.
내부 층의 방지 스케일링 성능을 어떻게 검증하나요?
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 single-screw extruder, typically diameter 45 to 90 millimeter with L/D 30 to 33 and a PP 장벽 스크류, 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.
어떤 Faygo 생산 라인이 주어진 직경과 층 구조에 적합할까요?
For 20 to 63 millimeter three-layer PPR the Faygo PP-R/PE-RT 파이프 압출 라인 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 파이프 압출 라인 product family and share vacuum calibration, planetary cutting and online inspection.
삼층 PPR의 일반적인 용융 온도와 교정 조건은 무엇입니까?
PP-R 기본 층은 배럴 영역에서 약 190~230℃로 가열되며, 유리 섬유 또는 EVOH 층은 점도와 일치하도록 다소 더 높게 가열됩니다. 다이에서 용융 압력은 15~30 MPa이며, 진공 보정은 냉각수 온도가 12~18℃인 상태에서 -0.02~0.06 MPa로 설정되며, 스프레이 탱크에서 출구 벽 온도는 하우오프 전에 40℃ 이하로 유지됩니다.
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.
결론
The domestic hot water system of a one-hundred-meter building asks more of its pipe than any low-rise network: it demands pressure resistance at the base, temperature endurance at the top, a bore that refuses to scale for fifty years, and a wall that does not buckle as it heats and cools. A three-layer composite anti-scaling PPR pipe answers all four by assigning each duty to its own layer, and the extrusion equipment that makes it is a synchronized co-extrusion system built around a stable extrusion group, a spiral mandrel die, vacuum calibration, steady haul-off and continuous inspection.
Faygo, Wanplas 공장 with twenty-two years of pipe and profile extrusion experience, builds this capability into its PP-R/PE-RT 파이프 압출 라인 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.
