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Product Description
Lay flat hoses are one of the fastest-growing segments in the global flexible piping market, driven by expanding agricultural irrigation networks across Asia, Africa, and Latin America — where drip and sprinkler system adoption is projected to grow at 9.2% CAGR through 2030. Beyond agriculture, these hoses serve construction site dewatering, mining slurry transfer, and firefighting water supply, making them a high-demand product category for plastic pipe manufacturers worldwide.
The key to lay flat hose performance lies in material selection and reinforcement structure:
PVC lay flat hoses: Dominant in cost-sensitive agricultural markets. A three-layer construction — inner PVC layer, polyester fiber reinforcement, outer PVC jacket — delivers working pressures of 3–8 bar at raw material costs of $800–1,000/ton. PVC hoses offer good chemical resistance and can be formulated for UV stability with TiO₂ or carbon black.
PE lay flat hoses: The preferred choice for potable water transfer and environmentally regulated markets. LDPE/LLDPE-based formulations are inherently flexible without plasticizers, non-toxic, and food-grade certifiable (NSF/ANSI 61, EU 10/2011). Working pressure 2–6 bar, with excellent low-temperature performance to -20°C.
PP lay flat hoses: Niche applications requiring higher temperature resistance (up to 80°C) and chemical inertness, though less common in irrigation due to higher material cost and lower flexibility.
All three materials share the defining structural advantage of lay flat hose — the fiber-reinforced three-layer wall collapses flat when drained, reducing storage and transport volume by approximately 80% compared to rigid hose of equivalent diameter. A 100-meter coil of 4-inch hose occupies roughly the same shipping volume as a 15-meter rigid pipe bundle.
The Chenxing Machinery PE/PVC Lay Flat Hose Extrusion Line integrates all production stages — from raw material mixing through granulating, three-layer co-extrusion with integrated fiber winding, vacuum calibration, spray cooling, haul-off, and dual-station automatic winding — into a single synchronized system controlled by Siemens PLC. Four standard models (SJ45 through SJ90) cover hose diameters from 1 inch (25 mm) to 8 inches (200 mm), with outputs from 25 to 180 kg/h. Explore our full product range for complementary equipment.
| Parameter | SJ45-LFH | SJ65-LFH | SJ80-LFH | SJ90-LFH |
|---|---|---|---|---|
| Screw Diameter (mm) | 45 | 65 | 80 | 90 |
| L/D Ratio | 28:1 | 30:1 | 30:1 | 33:1 |
| Hose Diameter (inch/mm) | 1"–2" (25–50) | 2"–3" (50–75) | 3"–5" (75–125) | 5"–8" (125–200) |
| Wall Thickness (mm) | 1.0–2.0 | 1.2–2.5 | 1.5–3.0 | 2.0–3.5 |
| Number of Layers | 3 (inner+fiber+outer) | 3 (inner+fiber+outer) | 3 (inner+fiber+outer) | 3 (inner+fiber+outer) |
| Working Pressure (bar) | 3–8 | 3–8 | 2–6 | 2–6 |
| Burst Pressure (bar) | 12–24 | 10–20 | 8–15 | 6–12 |
| Output (kg/h) | 25–45 | 50–80 | 80–120 | 120–180 |
| Line Speed (m/min) | 3–12 | 3–10 | 2–8 | 2–6 |
| Main Motor Power (kW) | 11 | 22 | 37 | 55 |
| Total Installed Power (kW) | ~35 | ~55 | ~85 | ~120 |
| Approx. Line Length (m) | 18–22 | 22–26 | 26–30 | 30–35 |
| No. | Component | Specification Details |
|---|---|---|
| 1 | Single-Screw Extruder (SJ Series) | 38CrMoAlA bimetallic screw & barrel, nitrided to surface hardness HV≥840, depth 0.5–0.7 mm. High-torque helical gearbox with NSK/SKF precision bearings. Siemens/ABB main motor with AC inverter drive. Siemens PLC + HMI touchscreen, PID multi-zone temperature control ±1°C, ceramic heater bands. L/D ratio 28:1 to 33:1 depending on model. Designed specifically for soft PVC LDPE LLDPE processing. See our single screw extruder and high-output extruder pages for detailed specifications. |
| 2 | Co-Extrusion Die Head (3-Layer) | 45# steel body hardened and polished, internal flow channels in 40Cr alloy steel, mirror-polished to Ra≤0.1 μm. Three-layer co-extrusion manifold — inner tube channel, fiber guide channel, outer jacket channel — converging into a single annular die. Stannum bronze calibration bushing for smooth inner bore surface. Independent temperature zones per layer with PID control. Die lip gap adjustable for wall thickness 1.0–3.5 mm. Quick-change bushing design — diameter swap within 30 minutes. Diameter range customizable from 25 mm to 200 mm. |
| 3 | Fiber Yarn Winding Unit | Polyester high-tenacity yarn (1,000–2,000 denier), 24–48 spindles on rotating creel stand. Cross-helical winding pattern at 54°–60° winding angle typical for lay flat hose. Mechanical or servo-controlled winding speed synchronized with extrusion line speed. Yarn tension individually adjustable per spindle at 200–500 g. Fiber layer is sandwiched between inner and outer extruded layers inside the co-extrusion die — yarn passes through guide ring into the melt stream for true three-layer fusion. |
| 4 | Vacuum Calibration & Spray Cooling Tank | SUS304 stainless steel tank, 4–8 m length depending on model. Stannum bronze vacuum calibration sleeve at entry for precise OD control. Multi-stage spray nozzles: Stage 1 — high-flow spray ring for rapid skin cooling; Stage 2 — gentle spray mist for gradual core cooling and stress relief. Water temperature PID-controlled at 15–25°C via recirculating chiller. Water-ring vacuum pump operating at -0.02 to -0.04 MPa. Adjustable height and center alignment. |
| 5 | Haul-off Unit (Belt/Caterpillar Type) | AC inverter-driven with frequency conversion speed control, range 2–12 m/min. Pneumatic clamping with rubber pads for non-marking grip on soft hose surface. Speed synchronized with extruder output and winder via centralized PLC. Effective traction length 1.0–2.0 m. Two pairs of belts for stable, even pulling force. |
| 6 | Double-Station Winder Unit | Dual-station automatic changeover for continuous production — one station winding while the other is ready. Constant tension control via torque motor or servo drive, maintaining 3–10 N tension regardless of coil diameter buildup. Lay-flat winding format — hose collapsed flat between nip rollers before winding. Coil OD up to 800–1,200 mm, coil width 300–500 mm. Adjustable traverse pitch for even coil build. Automatic cut-over and coil ejection. For standalone winding needs, see our pipe coiler. |
| 7 | High-Speed Mixer & Granulating Unit | SRL-Z high-speed mixer (200–500 L) for PVC compound blending — heats to 110–120°C via friction, auto-discharge to cooling mixer. Single-screw granulating extruder pelletizes the blended compound into uniform granules for stable downstream feeding. For PE hose production, direct pellet feed via vacuum loader without granulating step. Optional hopper dryer for moisture-sensitive materials. |
| 8 | Inline Inkjet Printer (Optional) | Continuous inkjet printer mounted before winder for product marking: hose diameter, working pressure rating, production date, batch number, standards compliance marks. |
Additional auxiliary equipment such as vacuum conveyors and material handling systems are available for full-line integration.
The heart of the line is the single co-extrusion die head that simultaneously forms the inner tube layer, embeds the polyester yarn reinforcement, and applies the outer jacket — all three layers fuse within one die, eliminating separate lamination steps. PVC hose delivers working pressure 3–8 bar and burst pressure 10–24 bar (3–5× higher than unreinforced hose of equivalent wall thickness). PE hose features a non-toxic food-grade inner layer with UV-stabilized outer jacket, suitable for potable water transfer. The lay-flat design collapses to approximately 20% of its filled volume, dramatically reducing warehousing and container shipping costs.
38CrMoAlA alloy steel screw nitrided to surface hardness HV≥840 at 0.5–0.7 mm case depth, paired with bimetallic barrel featuring high-chromium cast iron liner (HRC 58–62). This combination withstands over 50,000 operating hours with filled PVC/PE compounds containing CaCO₃ and other abrasive fillers. NSK/SKF precision bearings in the high-torque gearbox are rated for 24/7 continuous production. Screw geometry optimized with barrier flights for complete melting and homogenization of soft PVC and LDPE/LLDPE.
Single die head combines all three layers with independent PID-controlled heating zones per layer. 45# steel body hardened and mirror-polished; 40Cr internal flow channels achieve Ra≤0.1 μm surface finish to prevent material stagnation and degradation. Stannum bronze calibration bushing ensures a smooth inner bore critical for low-friction water flow. Die lip gap adjustable for wall thickness 1.0–3.5 mm across the full product range. Quick-change calibration bushing system enables diameter changeover within 30 minutes, minimizing downtime between production runs.
SUS304 stainless steel vacuum calibration tank with three-stage cooling: Stage 1 — vacuum sizing sleeve fixes outer diameter; Stage 2 — high-flow spray ring for rapid skin formation; Stage 3 — gentle spray mist for gradual core cooling and internal stress relief. Water temperature PID-controlled at 15–25°C. Cooling rate is critical for PE hose crystallinity — excessively rapid cooling induces internal stress and premature cracking, while insufficient cooling limits line speed. Spray pattern and flow distribution are independently adjustable per stage for different hose diameters.
Two winding stations with automatic changeover eliminate downtime for coil removal, enabling truly continuous production. Nip rollers collapse the hose into flat ribbon format before winding. Constant tension control maintains 3–10 N pull force regardless of coil diameter buildup. Standard coil dimensions: OD 800–1,200 mm × width 300–500 mm, weight 20–50 kg. Automatic cut-over triggers when coil reaches target size. Level-wind traverse mechanism ensures uniform coil build without edge bulging.
Single Siemens PLC with HMI touchscreen coordinates all line functions — extruder speed, fiber winding speed, haul-off speed, winder tension — from one control panel. Recipe memory stores 50+ product specifications with one-touch recall for repeat production runs. Real-time monitoring of melt temperature, melt pressure (19–25 MPa at die), cooling water temperature, and line speed, with alarm log and fault diagnostics for rapid troubleshooting. Optional Ethernet/4G remote monitoring for factory-wide production management. Compatible with downstream embossing and finishing equipment.
Step 1 — Raw Material Preparation
PVC hose: PVC resin (K-value 65–68) + DOP/DINP plasticizer (40–60 phr) + Ca-Zn stabilizer (3–5 phr) + CaCO₃ filler (10–30 phr) + lubricants + pigment → SRL-Z high-speed mixer → blend to 110–120°C → cooling mixer to 40°C → granulating extruder → uniform pellets. PE hose: LDPE/LLDPE granules + UV stabilizer (HALS, 0.2–0.5%) + carbon black masterbatch (2–3%) + processing aid → dry blended in low-speed mixer → direct feed without granulating.
Step 2 — Inner Tube Extrusion (Extruder A)
Compound pellets fed via hopper into SJ single-screw extruder operating at 160–190°C (PVC) or 180–220°C (PE). Plasticized melt enters co-extrusion die inner channel, forming the inner tube layer (0.4–1.2 mm thick).
Step 3 — Fiber Yarn Winding (Reinforcement Layer)
Polyester high-tenacity yarn from 24–48 spindles on rotating creel, tensioned at 200–500 g per spindle, threaded through guide ring. Cross-helical winding at 54°–60° angle around the inner tube as it passes through the die center. Yarn is embedded into the melt interface between inner and outer layers for full fusion. Winding speed synchronized with extrusion speed — faster winding increases yarn density and burst pressure.
Step 4 — Outer Layer Co-Extrusion (Extruder B)
Second single-screw extruder feeds plasticized melt into the co-extrusion die outer channel. Outer layer (0.4–1.5 mm thick) applied over the fiber-wound inner tube. All three layers fuse into a single wall inside the die at 170–190°C before exiting.
Step 5 — Vacuum Calibration & Spray Cooling
Hot hose enters SUS304 vacuum calibration tank, passes through stannum bronze calibration sleeve at -0.02 to -0.04 MPa for OD fixing and surface smoothing. Multi-stage spray nozzles cool the hose to 30–40°C over the 4–8 m tank length.
Step 6 — Haul-off
Cooled hose enters caterpillar haul-off unit. Pneumatic rubber pads grip without surface marking. Frequency-controlled speed synchronized with extrusion for consistent wall thickness.
Step 7 — Dual-Station Winding & Packaging
Hose passes through nip rollers, flattened into lay-flat ribbon, and wound onto spool at constant tension. Automatic station changeover at target coil size. QC inspection per ISO 1402 (burst pressure), OD/wall thickness measurement, and visual surface check. PE film wrapping and palletizing for export shipment.
PVC lay flat hose offers lower raw material cost (1,000–1,300/ton raw material) but is inherently flexible without plasticizers, can be formulated as non-toxic food-grade for potable water (NSF/ANSI 61 compliant), operates from -20°C to +60°C, and delivers excellent UV resistance with carbon black. For drinking water applications, PE is mandatory. For general irrigation where cost sensitivity is the primary concern, PVC is the standard choice. Both materials can be produced on the same extrusion line — switching requires die head and calibration bushing swap plus formulation change in the mixer, typically completed within one shift.
Fiber winding angle is measured relative to the hose axis. The neutral angle of 54°44' is theoretically balanced — at this angle, the hose neither expands nor contracts under pressure. Winding angles of 50°–54° cause slight contraction under pressure (length -2 to -5%) with higher burst pressure due to fiber alignment closer to the hoop direction. Angles of 55°–60° cause slight elongation (length +2 to +5%) with greater flexibility and easier coiling. Most agricultural hoses use 54°–56° for balanced performance. Winding density — yarn count per linear meter — is directly proportional to burst pressure: doubling yarn count yields approximately +70–85% burst pressure. Spindle count ranges from 24 to 48, with higher counts for larger diameters. Tension uniformity across all spindles is critical — ±10% tolerance per spindle, monitored by individual tension sensors on the creel stand.
Key international standards include ISO 1402 (burst pressure test — hose must withstand 4× working pressure minimum without rupture), ISO 8033 (adhesion test — peel strength between layers ≥1.5 N/mm), ISO 1307 (bore and OD tolerances: ±0.5 mm for diameters ≤50 mm, ±1.0 mm for 50–100 mm), and ISO 188 (accelerated aging at 70°C for 168 hours, tensile strength retention ≥80%). For PE potable water hose: NSF/ANSI 61 or EU Regulation 10/2011 for food contact materials. UV resistance: QUV accelerated weathering 1,000 hours, color change ΔE ≤5, tensile strength retention ≥85%. We provide third-party lab test reports (SGS/TUV) with each export shipment. In-house quality control includes 100% inline dimensional gauging, burst test sampling every 500 meters, and full visual inspection of every coil before packaging.
Flexible PVC lay flat hose formulation per 100 phr PVC resin (SG-3 or SG-5, K-value 65–68): DOP or DINP plasticizer — 45–55 phr (DINP preferred for low-temperature flexibility to -10°C, DOP for standard applications); ESBO co-stabilizer/secondary plasticizer — 3–5 phr; Ca-Zn stabilizer — 3–4 phr (replaces toxic lead stabilizers for RoHS/REACH export compliance); CaCO₃ filler — 15–25 phr at 800–1,250 mesh (content above 30 phr significantly reduces flexibility and burst pressure); TiO₂ rutile — 2–4 phr for white/light colors, or carbon black at 2% for black UV-resistant grades; stearic acid lubricant — 0.3–0.5 phr; PE wax — 0.2–0.3 phr. The critical difference from rigid PVC is plasticizer content approximately 20× higher (45–55 vs. 0–5 phr), eliminating the need for impact modifiers. Processing temperature runs 160–185°C versus 180–200°C for rigid PVC.
The SJ65 model producing 2"–3" hose delivers 50–80 kg/h, translating to approximately 1.2–1.9 tons per 24-hour day and 8,000–12,000 linear meters for 2" hose. The SJ80 model for 3"–5" hose outputs 80–120 kg/h or 1.9–2.9 tons/day, yielding approximately 6,000–9,000 meters for 4" hose. Standard export coil lengths are 50 m, 100 m, and 200 m (most common). Representative coil weights per 100 m: 2" PVC ≈ 18–25 kg, 3" ≈ 28–35 kg, 4" ≈ 40–55 kg, 6" ≈ 65–80 kg. Coil OD ranges from 600 to 1,200 mm depending on length and diameter. A 20-foot container accommodates approximately 18–22 tons of coiled hose. Utility consumption: cooling water 2–3 m³/h (recirculated), electricity 0.25–0.35 kWh/kg for PVC processing, compressed air at 0.6 MPa / 0.3 m³/min for pneumatic clamping. Two operators per shift are sufficient for one complete line.
Zhangjiagang Chenxing Machinery Co., Ltd. brings over 15 years of specialized extrusion engineering to every production line we deliver. Our approach combines deep material science expertise with practical manufacturing know-how:
In-house core technology: Every extruder screw, barrel, and die head is designed and manufactured in our own facility. We do not outsource critical components — this ensures quality traceability and rapid after-sales spare parts supply.
Application-tested formulations: We provide complete PVC and PE raw material formulations tested on our own pilot line before delivery, so your production team can begin commercial output within days of installation — not months of trial and error.
Siemens PLC standardization: All control systems use genuine Siemens components with English-language HMI, eliminating compatibility issues for overseas technicians. Remote diagnostic capability via Ethernet/4G reduces service response time.
Pre-delivery factory acceptance: Every line undergoes a full production trial at our facility — running your target hose specification with your formulation — before disassembly and shipment. You receive video documentation and sample coils from the trial.
End-to-end project support: From factory layout design and utility planning through installation supervision, operator training, and 12-month warranty with remote support, we remain your partner well beyond equipment delivery.
Learn more about our company, explore our solutions for complete factory setups, and browse our news section for recent installations and industry updates.
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Step 1 — Define Your Product: Tell us your target hose diameter range, material (PVC/PE/PP), and desired daily output (kg/day or meters/day). If you have a sample, share photos and specifications.
Step 2 — Receive a Customized Proposal: Our engineering team will recommend the optimal extruder model, line configuration, and provide a detailed quotation with delivery timeline within 2 working days.
Step 3 — Factory Acceptance Trial: Visit our Zhangjiagang facility or join via video call to witness your line producing your target hose specification before shipment.
Step 4 — Installation & Production: Our technicians supervise on-site installation and commissioning, train your operators, and stay until your line achieves stable commercial output.
Contact Nicole today to discuss your lay flat hose production requirements:
Phone / WhatsApp: +8615951187228
Email: ceo@cxsljx.com
Website: chenxingmachinery.com
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