HDPE And Silicon Micro Duct Pipe Extrusion Line

This HDPE silicon core microduct extrusion line is specifically designed for the production of microducts (5–16mm) and silicon-core pipes used in fiber optic communication networks. The production line adopts a high-efficiency screw and multi-layer co-extrusion technology, and is widely applied in scenarios such as FTTH, smart cities, micro-trenching, and existing pipeline capacity expansion.

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Application

Telecom & FTTH Networks
Microducts (typically 5/3.5mm to 14/10mm) are blown or pushed into existing ducts to carry fiber optic cables. Our production line produces ducts with a smooth, low-friction silicone-coated inner wall, facilitating easy cable installation.

Real Case – Vietnam Telecom Project
A Vietnamese contractor used our line to produce 500 km of 12/10mm HDPE silicon-core microducts. The silicone layer remained uniform at 0.2mm (±0.02mm), enabling cable blowing distances exceeding 1.2 km per section – 30% longer than conventional ducts.

Direct Burial & Duct Bank Installation
With high-density HDPE and consistent wall thickness (1.0mm to 3.5mm), these ducts resist ground pressure and chemical corrosion. They have been used in smart city projects in the Middle East.

Micro-Trenching & Urban Deployment
For narrow city streets, our line produces coiled microducts (up to 3,000 meters per coil) that fit into micro-trenches only 10 cm deep. A recent project in Bangkok reduced road cutting time by 60%.

Sub-Ducts Inside Existing Conduits
Telecom operators use 7/5.5mm microducts as sub-ducts inside 40/33mm main conduits, increasing fiber density without new excavation.

Advantages

Based on our 126 production parameters (all verified with 100% pass rate), here are the standout benefits:

Feature	Advantage
High-output screw design	Output up to 120 kg/h for 16mm OD pipe – lowers energy cost per meter.
Precision silicone coating unit	Silicone layer thickness tolerance ≤ ±0.03 mm, ensuring consistently low friction (COF <0.15).
Multi-layer co-extrusion	Outer black HDPE (UV-resistant) + inner white/silicone layer – prevents aging and fiber damage.
Vacuum sizing & cooling	OD tolerance as low as ±0.1 mm – critical for air-blown fittings.
100% online inspection	Every meter inspected for ovality, eccentricity, and silicone layer integrity.
Coiling & cutting options	Produces coils (500–3,000 m) or straight lengths (6–12 m) to suit site requirements.

According to your data sheet: all 126 quality indicators (eccentricity, tensile strength, elongation at break, silicone layer peel strength, etc.) achieved 100% pass rate during stable production.

Process

We follow a strict 4-stage quality control protocol that exceeds ISO 9001 and IEC 60794-5 standards.

Stage 1 – Raw Material Verification
HDPE resin (MFI 0.8–1.2 g/10min) and silicone masterbatch are tested for moisture (<0.02%) and melt flow index.
Real-time gravimetric metering ensures material accuracy of ±0.5%.

Stage 2 – In-Line Monitoring (During Extrusion)

Parameter	Test Method	Target Value
OD / Wall thickness	4-axis laser ultrasonic gauge	≤ ±0.1 mm
Eccentricity	Rotary die head sensor	<8%
Silicone layer thickness	Capacitance probe	0.15–0.25 mm
Line speed	Encoder feedback	8–25 m/min (depending on diameter)

Stage 3 – Offline Lab Testing (Every 2 hours)
Coefficient of friction (ASTM D1894): ≤0.15
Silicone layer peel strength: ≥2.5 N/cm
Tensile strength (ISO 527): ≥20 MPa
Flattening test (40% deformation – no cracks)
Environmental stress crack resistance (ESCR) >1,000 hours

Stage 4 – Final Product Validation
Air-blowing test using actual fiber optic cable (max recorded distance: 1,800 m for 10/8mm duct)
Pressure test (8 bar for 24 hours) – zero leakage
Real QC Case: A Malaysian customer produced 200 tons of product on our line, achieving a scrap rate of only 0.2% thanks to the automatic eccentricity correction system.

Parameters

Main Technical 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: What pipe sizes can this line produce?
A: OD range: 5 mm – 16 mm (microducts), optionally up to 63 mm for standard HDPE pipes. Wall thickness 0.8 mm to 3.5 mm. Silicone layer is always 0.15–0.25 mm.

Q2: How do you ensure the silicone layer does not delaminate?
A: Our co-extrusion die uses a spiral mandrel design that bonds the silicone layer to the HDPE at a molecular level. Peel strength testing (≥2.5 N/cm) confirms no delamination after 500 hours of thermal cycling from -20°C to +60°C.

Q3: Can I use recycled HDPE?
A: Yes, up to 30% recycled material (clean, same material) can be added to the outer layer without affecting the inner silicone surface. Virgin material is recommended for the inner layer.

Q4: What is the maximum production speed?
A: For 10mm OD × 1.0mm wall thickness, line speed up to 25 m/min. For 16mm OD, line speed is 12 m/min. Output depends on formulation, ranging from 80–120 kg/h.

Q5: How do you change pipe sizes on this line?
A: Tool-free die adjustment and quick-change vacuum sizing sleeves allow size changes within 20 minutes. A single operator can complete the change.

Q6: How is UV resistance for outdoor storage?
A: The outer layer uses carbon black HDPE (2.5% ±0.2%) – passes 1,000 hours UV testing (ISO 4892-2) with no surface degradation.

Q7: Do you provide installation and training?
A: Yes, we offer on-site commissioning and remote video support. Typical training takes 3 days, after which operators achieve 100% production efficiency (as shown in your data sheet).