Power Cable Extrusion Lines

-- Steady & Reliable Manufacturer --

Intro

Power cables are the backbone of every electrical grid — from low-voltage building wiring to high-voltage transmission infrastructure. Our Power Cable Extrusion Lines are designed to handle the full spectrum of power cable production, delivering the dimensional consistency, insulation quality, and production efficiency that cable manufacturers need to win and retain business from utility companies, electrical contractors, and infrastructure developers worldwide.

Our lines cover everything from simple PVC-insulated building wire (NYM, H07V-R) to complex medium-voltage cables with XLPE insulation, metallic screens, and LSZH sheaths. Whether you're running a high-volume commodity cable operation or a specialty MV cable plant serving utility tenders, we have a configured solution — and the engineering experience to make it work in your factory environment. Every line is engineered with proven components and backed by comprehensive after-sales support.

Specification

Cable Type Range	LV 0.6/1 kV to MV 35 kV
Conductor Range	1.5 mm² – 1,000 mm²
Extruder Screw Diameter	45 mm / 60 mm / 90 mm / 120 mm / 150 mm
Max. Extrusion Output	Up to 900 kg/hr (150mm screw, LDPE)
Temperature Control Accuracy	±0.5 °C per zone
Takeup Drum Capacity	Up to 10,000 kg (MV cable takeup)
Number of Extruder Heads	1 (single insulation) to 3 (triple co-extrusion)
Caterpillar Pulling Force	5 kN – 50 kN (model-dependent)
Water Trough Length	10 m – 60 m (configurable)
Compliance	IEC 60502, IEC 60228, BS 6346, NF C 32-321, VDE 0276

Application

Building & Construction Wiring (LV): High-speed production of PVC-insulated, PVC-sheathed cables (NYM, H07RN-F, NYY) for residential, commercial, and industrial buildings using our 45mm or 60mm extruder lines.
Distribution Cables (LV 0.6/1 kV): Manufacture multi-core aluminum or copper conductor cables with XLPE insulation and PVC or LSZH outer sheath for underground distribution networks.
Medium Voltage Cables (3.6/6 kV – 18/30 kV): Triple co-extrusion lines for XLPE-insulated, screened medium-voltage cables compliant with IEC 60502-2, including copper wire screen, aluminum foil, and LSZH or PE sheath layers.
Aerial Bundled Cables (ABC): Produce self-supporting aerial cables with XLPE or HDPE insulation for overhead distribution in urban and rural environments.
Industrial & Mining Cables: Manufacture flexible rubber-insulated cables (H07RN-F, NSHTÖU) for mobile machinery, mining equipment, and demanding industrial environments.
Instrumentation & Control Cables: Process multi-pair, individually screened cables for process industry control loops and instrumentation systems.

Advantage

Wide Product Range from One Platform: Modular screw and die design means a single extrusion line can cover LV building wire through to MV cables — protecting your capital investment as your product mix evolves.
Proven CV Technology for MV Cables: Our continuous vulcanization (CV) lines for XLPE cables use dry-curing nitrogen tube technology with precise pressure control, achieving low void content and clean conductor screen interfaces critical for MV cable partial discharge performance.
High Output Efficiency: Optimized screw geometry and barrel heater response deliver consistent melt quality at maximum throughput — our 90mm extruder achieves up to 400 kg/hr on LDPE without melt pressure fluctuation that causes OD variation.
Compact, Flexible Layouts: We offer both in-line (pay-off → extruder → trough → takeup) and L-shape or U-shape floor layouts for factories with limited length but adequate width, without sacrificing throughput or cooling efficiency.
Comprehensive After-Sales Network: Wear parts (screws, barrels, dies, tips) are stocked in regional warehouses. Standard wear parts ship within 24 hours; non-standard items within 2 weeks — minimizing production disruption.
Operator-Friendly HMI: 15" color touchscreen with recipe management stores up to 500 cable product recipes, enabling rapid product changeover by less-experienced operators without requiring engineering intervention.

Material & Structure

The structural integrity of a power cable extrusion line directly affects cable dimensional stability and long-term process consistency. Our line frames are fabricated from heavy-section rolled steel profiles, welded and stress-relieved before precision machining of all mounting surfaces. This eliminates frame distortion from thermal expansion during extended production runs.

The extruder barrel-and-screw combination is the heart of the line. For power cable applications, we use a nitrided steel screw with polished flights and a bimetallic barrel with 60% iron-based alloy liner — balancing cost with wear resistance for the abrasive LSZH and mineral-filled compounds increasingly specified by utility purchasers. For XLPE processing, the screw profile uses a barrier section and Maddock mixing head to achieve clean, void-free melt without overheating the peroxide crosslinking agent.

Main frame: Heavy rolled steel, stress-relieved, powder-coated RAL 7035
Extruder screw: Nitrided steel, Maddock mixing section for XLPE
Barrel: Bimetallic, Fe-based alloy liner, cast heaters with thermocouples
Water trough: 304 stainless steel, slotted bottom with adjustable supports
Caterpillar pads: Polyurethane or silicone, 60A Shore hardness standard
Control cabinet: IP54, UL-listed components optional

Installation Tips

Pre-Installation Civil Work: Power cable extrusion lines — especially MV CV lines — are among the longest pieces of equipment in any cable factory. Confirm your factory bay length matches the line layout drawing, accounting for 1.5 m clearance at each end for operator access and reel handling.
Crane Requirements: Extruder barrel and screw removal for maintenance requires an overhead crane rated for at least 2 tonnes at the extruder position. Confirm this is available before installation begins — retrofitting a crane after line installation is expensive and disruptive.
Compressed Air: Many functions (pneumatic takeup tension, die adjustment actuators, purging) require clean, dry compressed air at 6–8 bar. Install a refrigerated air dryer and coalescing filter at the line drop — moisture in the air circuit causes corrosion and unreliable pneumatic behavior.
Water Treatment: For the cooling trough, use softened or deionized water with a corrosion inhibitor approved for mixed metal systems (copper bus bars, stainless trough, mild steel supports). Hard water forms scale on trough walls and plugs spray nozzles within weeks.
Interlock Testing Before First Run: Test every safety interlock independently — e-stop chain, guard door switches, caterpillar overload relay, and temperature over-limit cutouts — and document the test results before any plastic is melted. This is non-negotiable from both a safety and an insurance perspective.
Die Purging Procedure: When changing from PVC to XLPE or vice versa, always purge with a compatible transition compound. Never leave XLPE compound stationary in a hot barrel — cross-linking will occur within minutes at operating temperature, creating a solid plug that can take hours to clear.

Comparison with Similar Products

Power cable extrusion is a competitive market, and buyers typically evaluate multiple suppliers. Here's a frank assessment of how our lines compare:

vs. Rosendahl / Nokia / Maillefer (European Premium): These brands represent the highest tier of cable machinery engineering, particularly for EHV (extra-high voltage) cables above 66 kV. For LV and MV cable production up to 35 kV, our lines deliver equivalent dimensional accuracy and process control at 40–60% lower capital cost, with faster delivery and more flexible customization options. If your business case requires EHV capability, we recommend an honest conversation about project scope before comparing.
vs. Chinese Entry-Level Suppliers: The Chinese cable equipment market ranges enormously in quality. Our distinguishing features include: genuine Siemens/Mitsubishi control systems (not clones), full PLC source code delivery, third-party-inspected build quality, and a post-sale service network. We also provide a written performance guarantee on key parameters (OD tolerance, line speed) — something very few low-cost suppliers offer.
vs. Refurbished European Lines: Used European machinery can be attractive on price but comes with significant risks — outdated controls, unavailable spare parts, and unknown remaining service life of screws and barrels. Our new lines offer modern HMI, current communication protocols, and a full warranty with defined spare parts availability for at least 10 years.
Total Cost of Ownership: When factoring in energy efficiency (VFD drives on all axes), screw/barrel service life (minimum 5 years for standard applications), and downtime costs, our lines typically show a payback advantage within 3–5 years versus both premium European and low-cost alternatives.

FAQ

Q: What voltage ratings can your extrusion lines support for power cable production?
A: Our standard range covers LV cables (0.6/1 kV) through medium-voltage cables up to 35 kV. For cables in the 35 kV range, we supply triple co-extrusion lines with dry-cure CV tubes designed to meet IEC 60502-2 partial discharge and dielectric test requirements. For voltages above 36 kV, please contact our engineering team to discuss a project-specific solution.

Q: Can we produce both PVC and XLPE cables on the same line?
A: Yes, with screw and die changes. PVC and XLPE require different screw geometries (compression ratios, mixing sections), and it's not advisable to run both compounds in the same screw without changing it. We supply the line with a screw set for each compound type, and changeover typically takes 2–4 hours including purging. For factories running frequent compound changes, we offer a dual-screw holder fixture that speeds up the mechanical changeover.

Q: What OD tolerance can we expect on finished cable?
A: For standard LV cables (e.g. 16 mm² NYY), our lines consistently achieve OD tolerance of ±0.2 mm or better under stable production conditions. For MV cable insulation layers, our triple co-extrusion systems with inline laser gauges achieve ±0.15 mm on the insulation layer OD. Actual results depend on compound consistency from your material supplier, which is always a factor we discuss during the project review phase.

Q: How do you handle after-sales service and spare parts supply?
A: We maintain a parts inventory for all lines we have sold for a minimum of 10 years from delivery. Common wear parts (screws, dies, tips, caterpillar pads, thermocouples) are stocked in regional warehouses and ship within 24–48 hours. Electronic components (HMI screens, servo drives, PLC modules) from our approved suppliers (Siemens, Mitsubishi) are commercially available worldwide, so you're never dependent on us alone for sourcing them.

Q: Do you offer turnkey project management including civil work coordination?
A: We provide full turnkey project services: factory layout planning, civil specification drawings, equipment supply, installation supervision, commissioning, operator training, and production qualification runs. We coordinate with your local civil contractor for foundation and utility preparation. Turnkey projects typically add 4–8 weeks to the timeline versus equipment-only supply, but significantly reduce the risk of delays caused by interface issues between civil and mechanical work.