T8 LED replacement
Standard 600mm or 1200mm lamp covers for LED retrofit fixtures.
LIGHTING TUBE
How PC LED Lighting Tube Is Made
From polycarbonate pellet to high-clarity T8 lamp tube.
PC lighting tube replaces glass in LED fittings because it is clear, impact-resistant and safer to handle. The production line must protect optical quality, not only produce kilograms per hour.
What PC lighting tube is used for
Lighting tube is produced as clear tube for direct LED visibility or diffused milky tube for even light distribution. Clear tube often targets light transmittance above 88%, while diffused tube may be 50-70% depending on haze.
T5 slim lighting
Small-diameter clear or diffused tube for compact fixtures.
Architectural linear lighting
Long covers where surface marks and light stripes are unacceptable.
Commercial display lighting
Optical covers for shelves, signs and illuminated displays.
Raw material: PC or PMMA pellets
Polycarbonate is highly hygroscopic and must be dried before extrusion. Even 0.05% moisture can hydrolyse PC at processing temperature and create bubbles, silver streaks or weak tube walls. A dehumidifying hopper dryer is normally set around 120°C for 4-6 hours, with final moisture below 0.02%. PMMA is used when higher optical clarity is required, but it has lower impact resistance than PC and processes at about 220-250°C.
- PC processes at 260-300°C, higher than PVC, PE or PPR.
- Diffuser masterbatch must be dispersed evenly or the tube will show visible light bands.
- Regrind should be limited because optical parts reveal degradation quickly.
Production process
PC tube extrusion is about precision and surface protection. Water contact on a hot PC tube can leave permanent marks, so dry vacuum sizing and servo haul-off are preferred.
Drying
PC pellets are dried at about 120°C for at least 4-6 hours. This step is not optional; wet PC degrades visibly during extrusion.
Single-screw extrusion
A low-compression single screw melts PC at 260-300°C. High shear is avoided because PC can yellow or lose impact strength when overheated.
Precision tube die
The die must hold wall variation below about 0.1mm so light transmission remains even around the tube circumference.
Dry vacuum sizing
Dry sizing fixes tube diameter without water contact. This protects the hot optical surface from water marks.
Cooling
Controlled air or downstream cooling stabilizes the tube after sizing. The goal is slow, even shrinkage.
Servo haul-off
Speed variation creates light stripes because wall thickness changes. Servo haul-off is preferred over simple belt drive.
Guillotine cutting
The tube is cut to standard lighting lengths such as 600mm or 1200mm with a clean, square end.
Finished tube requirements
Finished PC lighting tube is inspected for transparency, haze, wall thickness, straightness, bubbles, streaks and surface scratches. Clear tube prioritises high transmittance, while diffuser tube balances transmittance with light uniformity. Because LED products expose the tube directly to the customer, small extrusion defects that would be acceptable in pipe are rejectable in lighting tube.
Machines required
These are the core machines for a PC lighting tube line. The key difference from ordinary pipe extrusion is drying, precision die design, dry sizing and servo-controlled haul-off.
Single Screw Extruder (PC grade)
Processes PC or PMMA with low shear and tight temperature control.
PC Tube Die Head
Forms thin-wall optical tube with low wall variation.
Dry Sizing Unit
Calibrates OD without water marking the surface.
Precision Haul-off
Controls wall consistency and visible light stripe quality.
Guillotine Cutter
Cuts optical tube to lamp lengths without crushing.
Technical reference
Planning reference only. Final configuration depends on your target spec — share it with the engineering team for a matched proposal.
| Tube diameter | Ø16-76mm |
|---|---|
| Output rate | 30-150 kg/h |
| Wall thickness | 0.8-2.5mm |
| Light transmittance | >88% for clear PC tube |
| Processing temperature | PC 260-300°C / PMMA 220-250°C |
| Drying target | <0.02% moisture before processing |
Ready to produce PC LED lighting tube?
Tell us your tube diameter, wall thickness, clear or diffused type, target transmittance and output rate. We will configure drying, extrusion, sizing and cutting equipment for your product.
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