company news about Split VS. Integral Layouts: How to Select Based on Workshop Space?

Split VS. Integral Layouts: How to Select Based on Workshop Space?

The layout design of welded pipe mills directly impacts workshop utilization and production efficiency. This article analyzes the space requirement differences between ZY series integral type (ZY16-ZY32) and split type (ZY45-ZY89) machines, providing a selection logic for different workshop conditions to avoid production bottlenecks caused by improper layout.

I. Core Layout Differences: Space Occupancy and Functional Zoning

II. Workshop Space Adaptation Guide: Analysis of Three Typical Scenarios

1. Small Workshops (Area ≤100㎡, Height 4-5m): Prioritize Integral Type

Suitable Scenarios：

• Small and medium factories in urban industrial zones (e.g., Delhi, India; Jakarta, Indonesia), often in leased or renovated spaces with limited room.
• Typical Case: A Vietnamese furniture factory with 80㎡ workshop adopted ZY20 integral type (60㎡ footprint), achieving fast switching between φ16-φ26mm pipes via side-pull roll changing, with 300 tons/month capacity and 40% higher space utilization.

Core Advantages：

• Compact Design: No extra accumulator module, linear layout suitable for narrow spaces;
• Low Renovation Cost: Fits standard 4m-height workshops without raising ceilings or expanding floors;
• Flexible Production: 15-minute roll change for multi-specification small batches, avoiding "overkill" of split types.

Model Recommendations：

• ZY16 (φ8-φ18mm): Ideal for precision pipes like bathroom branch pipes;
• ZY32 (φ12.7-φ38.1mm): Covers agricultural machinery pipes, 15 tons/single shift.

2. Medium Workshops (Area 100-200㎡, Height 5-6m): Choose Transition Solutions as Needed

Suitable Scenarios：

• Factories in township industrial zones (e.g., Hebei, China; Mumbai, India), balancing current space and future expansion.
• Comparison Cases：
  • Integral Type (ZY45): An Indian steel structure factory uses ZY45 integral type (80㎡ footprint) for φ50mm scaffolding pipes, with $150,000 initial investment meeting 800 tons/month orders;
  • Split Type (ZY50): Requires additional 4.2m-diameter horizontal accumulator (+30㎡ footprint), 20% higher initial cost but 30% more continuous production efficiency.

Decision Logic：

• Multi-specification Production: Choose integral type, ZY45’s double-radius pass covers φ12.7-φ50.8mm with low model change cost;
• Single-specification Expansion: Choose split type ZY50, 200m accumulator capacity supports 24/7 production for stable construction pipe orders.

3. Large Workshops (Area ≥200㎡, Height ≥6m): Split Type Unlocks Capacity Ceiling

Suitable Scenarios：

• Park-type factories or export-oriented enterprises (e.g., Middle East oil field suppliers, Southeast Asian infrastructure vendors), needing high-volume orders and international certifications.
• Typical Application:
  • ZY89 split layout (120㎡ footprint): A Middle Eastern petrochemical plant uses it for φ102mm oil transmission pipes, with 300kW HF welder and hydrostatic tester, annual capacity 12,000 tons;
  • Layout Advantage: Independent forming-sizing transmission and accumulator buffer production fluctuations, 50% higher per capita capacity than integral type.

Key Configurations：

• Horizontal Spiral Accumulator: 5m diameter (ZY89), feeding speed ≥150m/min to avoid downtime;
• Hydraulic Uncoiler: Supports 5-ton coils, reducing loading frequency for 24-hour unattended production.

III. Pitfall Avoidance: Three "Non-Negligible" Points in Space Planning

1.Maintenance Passage Reservation：

• Integral type: Leave 1.5m passages on both sides for side-pull roll changing;
• Split type: Maintain 2m safety distance around accumulator for hydraulic system maintenance.

2.Power and Drainage Pre-Burial：

• Split type ZY76-ZY89 requires independent hydraulic station (power ≥132kW), plan dedicated power lines in advance;
• Integral type cooling fluid flow ≥10 tons/hour, embed drainage trenches (slope ≥3%).

3.Future Expansion Interfaces：

• Integral type can upgrade via "modular stacking" (e.g., ZY32 + online punching module) without rebuilding the workshop;
• Split type needs early planning for expansion space (e.g., reserve second-phase accumulator location) to avoid repeated infrastructure costs.

Zhongyue Metallurgy Equipment Technology Co., Ltd, based in Zhangjiagang, China, pioneers precision metallurgical equipment manufacturing. With 150+ annual productions, our high-frequency welded pipe mills and H-beam lines empower automotive, medical, and renewable energy industries. Committed to R&D excellence and customer-centric innovation, we drive smart manufacturing evolution globally.