EN
HDPE Spray-Winding Line DN400-2000 | PE Jacket for Pre-Insulated Pipe Production
Monolithic PE-on-PU bonding, zero air gaps. DN400-2000mm, 300-800 kg/hr extrusion. Synchronized PLC winding pitch. 250-450 kW. CE/ISO 9001/TUV. Unlimited diameter, no pre-made sleeve needed.
- Overview
- Technical Specifications
- Application Scenarios
- Service and Support
- Recommended Products
Overview
Why Spray-Winding Replaces Tube-in-Tube
The tube-in-tube method has a fatal flaw: the air gap. Traditional pre-insulated pipe manufacturing inserts a steel carrier into a pre-made HDPE sleeve, then injects PU foam between them. The gap between PU and HDPE creates a path for moisture migration that can travel the entire pipeline. This spray-winding line eliminates the gap entirely: hot HDPE is extruded and wound directly onto the PU insulation surface while both materials are hot, creating a 100-percent monolithic bond. No gap means no moisture path, no delamination, and no hidden corrosion.
◆ Unlimited Diameter, Zero Sleeve Inventory. Tube-in-tube is limited by available pre-made HDPE sleeve sizes. This spray-on winding line produces any diameter on demand up to DN2000mm and beyond. No pre-made sleeve inventory, no mold investment, no diameter constraints.
◆ Monolithic PE-PU Bond. Hot HDPE wound onto the warm PU foam surface creates a chemical and mechanical bond. If the outer jacket is punctured during handling, water cannot migrate along the pipe because there is zero gap for it to travel through.
◆ Synchronized PLC Control. The pipe rotation speed and extrusion carriage travel speed are precisely synchronized by the PLC. The spiral winding overlap, pitch, and thickness remain perfectly consistent across the entire 12-meter pipe length.
◆ Optional Flattening Roller. A specialized roller downstream of the extrusion head smooths the spiral winding overlap, producing a dense, smooth outer surface that meets international standards for appearance and performance.
Spray-Winding vs. Tube-in-Tube Manufacturing
Feature |
Spray-Winding Line |
Tube-in-Tube Method |
Bonding |
100 percent monolithic PE-PU bond |
Air gap between PU and sleeve |
Moisture Migration |
Zero, no gap for water |
Water travels through gap entire pipe |
Diameter Flexibility |
Unlimited, any OD on demand |
Limited to pre-made sleeve sizes |
Inventory |
No sleeve inventory needed |
Stock every diameter sleeve |
Material Efficiency |
Precise thickness control |
Over-sized sleeves waste material |
Automation |
Synchronized PLC winding |
Manual sleeve insertion |
Quality Consistency |
PLC-controlled pitch and overlap |
Dependent on operator |
Technical Specifications
|
Parameter |
Standard / Value |
|
Technology |
Continuous spiral spray-on winding |
|
Pipe Range |
DN400mm - DN2000mm (larger upon request) |
|
Material |
High-Density Polyethylene (HDPE) |
|
Max Pipe Diameter |
DN2000mm (customizable beyond) |
|
Extrusion Capacity |
300 kg/hr - 800 kg/hr (extruder dependent) |
|
Rotary Support |
Multi-tire heavy-duty synchronized rollers |
|
Layer Thickness |
Adjustable per project specification |
|
Installed Power |
250 kW - 450 kW |
|
Standard Pipe Length |
12 meters (container standard); 18m optional |
|
Control System |
Synchronized PLC with touch screen |
|
Optional |
Flattening roller for smooth surface finish |
|
Certifications |
CE, ISO 9001, TUV |
|
Packaging |
Containerized with protection and manuals |
Application Scenarios
District Heating Primary Networks. Produce large-diameter pre-insulated pipes with monolithic PE-on-PU bonding. Zero moisture migration means 30-50 year service life for municipal heating infrastructure.
District Cooling Pipes. Same spray-winding line produces chilled water pipes for airport, campus, and data center cooling networks.
Oil and Gas Thermal Pipelines. Produce insulated pipes for hot oil transport. Monolithic bond prevents corrosion under insulation in buried service.
Trusted Across 110+ Countries
Our spray-winding lines are installed in pre-insulated pipe factories worldwide. CE, ISO 9001, and TUV certified. Complete installation manuals, video tutorials, and on-site engineer training available
Service and Support
|
Service Item |
Details |
|
Pre-Sales |
Line configuration, extruder sizing, diameter range planning, utility requirements analysis. |
|
Free Samples |
Video demonstration and factory visit welcome. Test production runs available. |
|
Production QC |
100 percent factory-tested before shipment. CE, ISO 9001, TUV certified. |
|
Delivery |
Manufacturing lead time confirmed per order. Containerized shipment. EXW, FOB, CIF. |
|
MOQ |
One complete line per order. |
|
Technical Support |
Engineer on-site installation, operator training, PLC programming, flattening roller setup. |
|
After-Sales |
12-month warranty. Spare parts always in stock. Lifetime technical consultation. |
|
Payment |
T/T, L/C at sight. Flexible for long-term partners. |
|
OEM |
Custom diameter range, extruder size, and labeling available. |
