25 March 2026 · 8 min
Every procurement decision in chemical processing carries engineering risk. When it comes to fluid handling lines, choosing the wrong tubing construction (lined versus full-bore PTFE) can mean overspending on capability you don't need, or under-specifying for an application that demands more. This analysis breaks down both options across cost, performance, and typical use cases.
Understanding the Two Constructions
PTFE lined tubing features a metallic outer shell (typically carbon steel or stainless steel) with an internal PTFE liner. The metal provides structural strength while the PTFE handles chemical contact. Full PTFE tubing is manufactured entirely from virgin PTFE resin, with no metallic component in the fluid path or wall structure.
Five Critical Factors Compared
| Factor | PTFE Lined | Full PTFE |
|---|---|---|
| Upfront Cost | 40–60% lower for large diameters | Higher: all-PTFE material throughout |
| Temperature Range | Practically limited to +200°C (thermal expansion concern) | –200°C to +260°C continuous |
| Chemical Resistance | Equivalent at fluid contact surface | Through-wall protection; no metallic path |
| Pressure Rating | 50+ bar (metal shell provides strength) | Typically 10–15 bar (PTFE only) |
| Flexibility / Routing | Rigid pipe installation approach | Flexible; easily routed in small bores |
Cost Consideration
Lined tubing costs 40–60% less for larger-diameter pipelines because only the inner contact surface uses PTFE resin, the expensive material. For a 50mm pipeline, this translates to a meaningful project-budget saving. However, for small-bore tubing (under 10mm), the cost difference narrows significantly and full PTFE becomes competitive when total lifecycle cost is considered.
When Full PTFE Is Mandatory
- Pharmaceutical and cryogenic applications where permeation through the tube wall would cause contamination: the metal shell in lined tubing offers no permeation protection.
- Precision instrumentation and analytical equipment where full dimensional flexibility and miniature sizing are required.
- Any application where complete purity across the tube wall is a compliance requirement.
- Small-bore applications below 25mm OD where the lined construction offers diminishing cost advantages.
Quick Selection Guide
If your operating pressure is below 15 bar, diameter below 25mm, or application is pharmaceutical or analytical: specify full PTFE. For large-bore (50mm+), high-pressure industrial pipelines where only the bore contacts the fluid: PTFE lined is typically the economic choice.