HDPE And Silicon Micro Duct Pipe Extrusion Line

Jwell’s twin extrusion line is specifically designed for producing HDPE (High-Density Polyethylene) silicon duct pipes and micro ducts, widely used in optical cable networks, FTTH projects, and telecommunications infrastructure.

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Application

Our twin extrusion line is engineered for manufacturing HDPE silicon duct pipes and micro ducts, extensively applied in optical cable networks, FTTH projects, and telecom infrastructure.
Model JW65/33 + JW54/33 (Pipe diameter range: 7–20 mm, max speed: 120 m/min)
Suitable for last-mile micro ducts (e.g., 10/8mm, 12/10mm, 14/12mm) for residential broadband, curb-to-home fiber installation, and indoor/outdoor micro optical cables.
Real case: A Thai telecom contractor used this line to produce 12/10mm silicon ducts at 115 m/min, reducing production time by 30% in a 200 km FTTH project.
Model JW75/38 + JW65/33 (Pipe diameter range: 110–250 mm, max speed: 6 m/min)
Designed for large-diameter HDPE conduits (e.g., 160/140mm, 200/180mm, 250/230mm) for backbone optical cable tunnels, railway crossings, and heavy-duty underground protection.
Real case: A Middle Eastern utility company adopted this model to produce 200mm silicon ducts for a 50 km desert fiber backbone, ensuring zero collapse under high sand load.

Advantages

Feature	Advantage
Two-stage extrusion (JW65/33 + JW54/33)	Superior plasticization – ensures uniform silicon layer adhesion even at 120 m/min.
High-speed capability (7–20mm line)	Output up to 7,200 m/hour, ideal for high-volume micro duct orders.
Heavy-duty screw design (JW75/38 + JW65/33)	Handles up to 250mm OD at low speed (6 m/min) → precise wall thickness control for large, thick-walled pipes.
Silicon coating uniformity	Patented spiral die guarantees ±0.05mm silicon layer consistency, reducing frictional resistance for fiber blowing.
Energy-saving cooling	Multi-section vacuum sizing tank reduces energy consumption by 18% compared to conventional lines.

Competitive advantages: The 120 m/min micro duct line reduces labor and overhead costs by 25% per meter; the large-diameter line’s low speed enables extreme wall thickness (up to 25mm) for direct burial in rocky terrain.

Process

We implement real-time monitoring and end-of-line testing to meet ISO 4427, ASTM D3035, and customer-specific standards.

In-line process quality control (automated)

Ultrasonic wall thickness scanner – Measures ID, OD, and eccentricity every 0.5 seconds. Triggers alarm when deviation exceeds ±0.1mm.

Melt pressure & temperature logging – For each extruder (33 L/D ratio ensures stable melt flow).

Silicon layer thickness detector – Non-contact laser sensor continuously checks coating; automatically rejects if <0.3mm or >0.7mm.

Offline testing (every 500 meters)

Test Item	Standard	Equipment
Tensile strength	≥20 MPa (HDPE)	Universal testing machine
Silicon layer peel strength	>50 N/25mm	Peel tester
Flattening test (40% deformation)	No cracks	Hydraulic press
Environmental stress crack resistance (ESCR)	1000 hrs @ 80°C, 4 MPa	ESC test chamber
Coefficient of friction (silicon layer)	≤0.15	COF tester

Real case: For a 180 km Indonesian order, we produced 14/12mm micro ducts at 118 m/min. Samples were taken every 2 km for fiber blowing test (1.3mm fiber, 8 bar air pressure) – blowing distance exceeded 1,100 meters, surpassing the customer’s 800 m requirement.

Parameters

Model	Duct pipe(mm)	Maxim production speed(m/min)
JWS65/33+JWS45/33	7-20	120
JWS75/38+JWS65/33	110-250	6

Q1: Why can the large-diameter model (110–250mm) only run at 6 m/min?
A: Larger OD requires thicker wall thickness (up to 25mm) and longer cooling time. Low speed ensures dimensional stability and prevents ovality. At 6 m/min, the line outputs ~360 m/hour – sufficient for heavy-duty pipes (typical demand is 500-1000 m/day).

Q2: Can the JW65/33 + JW54/33 line produce multi-duct (combination) pipes?
A: Yes. With an optional co-extrusion die, it can produce 2, 4, or 7-hole micro ducts within 7–20mm OD. Maximum speed reduces to 80-90 m/min depending on the number of holes.

Q3: How long is the silicon layer adhesion life?
A: Accelerated aging tests (70°C, 672 hours) show no adhesion loss. In actual projects installed since 2018, silicon layer peel strength remains >45 N/25mm.

Q4: How do you handle raw material variations (recycled HDPE)?
A: The 33:1 L/D screw with mixing sections can process up to 30% post-industrial recycled material without speed reduction. We recommend using a screen changer to remove impurities.

Q5: What power supply is required?
A: Standard 380V/50Hz (customizable to 460V/60Hz). Total installed power: JW65/33+JW54/33 = 185 kW; JW75/38+JW65/33 = 310 kW.

Q6: Do you provide installation training?
A: Yes – we dispatch two engineers for 15 days of on-site training, including calibration of the vacuum sizing tank for 6 m/min operation to avoid pipe sagging.