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Core Wire Insulation Extrusion Line Manufacturer

Core Wire Insulation Extrusion Line

■ Used widely: Used for conductor single layer/single layer+striping insulation extrusion.

High output: Optimizing screw design, Screw durability, non-cohesive gel, non-take off a chrome, color change quickly, high wire speed, high output.

■ High quality: Extrusion concentricity: over 93%; OD tolerance:+/-0.005mm.

Temperature control precision: Adopted SCR power control machine with imported high-quality temperature control table, the machine temperature is controlled within +/-1℃.

■ Easy control: Intelligent control wire diameter auto-teedhack and adjustment hommization machine desian comhined with NEWTOPP specialized touch screen make machine operation easier and more convenient.

■ Save space: Combine traditional accumulators, capstan, take-ups, meter counter, and so on, auxiliary devices into an integrated structure. The layout is compact. The overall length will reduce by over 5M.

Core Wire Insulation Extrusion Line
  • Core Wire Insulation Extrusion Line
  • Core Wire Insulation Extrusion Line
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NewTopp Precision Jiangsu NewTopp Precision Machinery Co., Ltd.
Jiangsu NewTopp Precision Machinery Co., Ltd.
Since its establishment in 2004, Jiangsu NewTopp Precision Machinery Co., Ltd. has specialized in the research, development, design, and manufacturing of high-end cable equipment. After more than a decade of development and continuous effort, our company has grown to encompass three manufacturing plants, an IoT technology company, and the Kunshan Newtopp branch.
Newtopp Precision is a National High-Tech Enterprise and has obtained ISO9001 quality certification and ISO14001 environmental management system certification. Covering 50 acres, the company boasts an independent R&D center, a finishing center, and a paint booth, integrating R&D, design, manufacturing, and sales. We are committed to providing customers with high-quality products and excellent service.
As a professional China Core Wire Insulation Extrusion Line Manufacturer and Core Wire Insulation Extrusion Line factory, Our company's sustainable development along the way is inseparable from the support and trust of our customers. The large enterprises have long-term cooperation with many customers from all walks of life.
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The Core Wire Insulation Extrusion Line is a core equipment series developed by Jiangsu Newtopp Precision Machinery Co., Ltd. for cable conductor insulation processing, designed to realize high-precision, high-efficiency single-layer or single-layer+striping insulation extrusion. As a National High-Tech Enterprise specialized in high-end cable equipment R&D and manufacturing, Newtopp has integrated over a decade of technical experience into the Core Wire Insulation Extrusion Line, ensuring its compliance with ISO9001 quality management system standards. This equipment series has become a key choice for manufacturers in automotive cables, new energy cables, data transmission cables and other fields due to its stable performance and compact structure, and the Core Wire Insulation Extrusion Line also stands out in the global market with its core advantages of high output, high precision and space saving.

1. Working Principle of Core Wire Insulation Extrusion Line
The Core Wire Insulation Extrusion Line operates based on the principle of "melting-extrusion-forming-cooling-winding", and Newtopp has optimized each link with professional technology:
  1. Conductor Feeding: The cable conductor is stably fed through the pay-off device, and the tension control system independently developed by Newtopp ensures that the conductor remains straight and stress-free during operation, laying the foundation for insulation concentricity.
  2. Material Melting & Conveying: The extruder screw, designed and optimized by Newtopp’s R&D team, adopts high-wear-resistant materials and a special thread structure. It efficiently conveys, melts and plasticizes insulation materials (such as PE, PVC, Teflon) while avoiding material adhesion and screw chrome peeling.
  3. Precision Extrusion: The molten insulation material is extruded onto the conductor surface through a high-precision die. The SCR power control system and imported temperature control table adopted by the equipment realize ±1℃ temperature control precision, ensuring uniform material melting and stable extrusion pressure.
  4. Shaping & Winding: After extrusion, the insulated conductor is cooled by a water tank to solidify the insulation layer, then the intelligent wire diameter detection system (with automatic feedback and adjustment function) monitors the outer diameter in real time, and finally the integrated take-up device completes the winding.
Newtopp’s Core Wire Insulation Extrusion Line integrates the core technologies of its independent R&D center, such as intelligent control system and integrated structural design, which not only simplifies the operation process but also improves the consistency of product quality.

2. Application Cases
Leveraging its rich experience in serving multiple high-end cable fields, Newtopp’s Core Wire Insulation Extrusion Line has been widely applied in the following typical scenarios:
Application Field Cable Type Customer Demand Equipment Performance Advantage
Automotive Industry Automotive wiring harness conductors High insulation concentricity (≥93%), stable performance under high temperature OD tolerance ±0.005mm, temperature control precision ±1℃, meets automotive electronics reliability requirements
New Energy Industry EV charging cable cores High output, fast color change, environmental protection compliance Optimized screw design improves production efficiency by 30% compared with traditional equipment; quick color change function reduces material waste
Data Communication Industry Cat5e/Cat6 data cable conductors Striped insulation (for signal identification), high dimensional accuracy Supports single-layer+striping extrusion; intelligent diameter control ensures consistent signal transmission performance
Industrial Control Industry Robotic cable cores Wear-resistant insulation layer, compact equipment layout Screw with non-cohesive gel design ensures insulation material purity; integrated structure saves 5M+ factory space
These cases fully verify the adaptability of the Core Wire Insulation Extrusion Line to different application scenarios, and Newtopp’s cooperation with long-term partners (including large enterprises in the cable industry) also proves the equipment’s market recognition.


3. Product Performance Comparison (Newtopp vs. Traditional Equipment)
To help customers intuitively understand the advantages of the Core Wire Insulation Extrusion Line, the following comparison is made with traditional insulation extrusion equipment based on Newtopp’s actual test data and customer feedback:
Performance Indicator Newtopp Core Wire Insulation Extrusion Line Traditional Insulation Extrusion Equipment Advantage of Newtopp
Insulation Concentricity ≥93% 85%-90% Higher concentricity reduces signal attenuation, suitable for high-precision cables
OD Tolerance ±0.005mm ±0.01-0.02mm More precise dimensional control, meets high-end cable quality standards
Temperature Control Precision ±1℃ ±3-5℃ Stable melting temperature ensures uniform insulation thickness
Equipment Overall Length Reduced by ≥5M compared with traditional models Longer (integrated with separate auxiliary devices) Compact layout, saves factory space, reduces installation costs
Wire Speed & Output High wire speed, 30% higher output General wire speed, limited output Improves production efficiency, shortens delivery cycle
Color Change Efficiency Fast color change, low material waste Long color change time, high waste Reduces production downtime and material costs
Operation Difficulty Intelligent touch screen control, automatic diameter adjustment Manual operation, complex parameter setting Lowers skill requirements for operators, reduces human error
Note: The data in the table is derived from Newtopp’s laboratory test results and third-party detection reports, and the comparison objects are mainstream traditional equipment in the market (non-low-end products).


4. Maintenance Guide

To ensure the long-term stable operation of the Core Wire Insulation Extrusion Line, Newtopp provides professional maintenance suggestions based on ISO14001 environmental management system requirements and equipment structural characteristics:

4.1 Daily Maintenance (Before/After Operation)

  • Check the temperature sensor, pressure gauge and other components for normal operation; ensure the SCR power control system is free of abnormal heating (Newtopp’s equipment adopts high-quality imported sensors with longer service life).
  • Inspect the screw and barrel for material residues; clean them in time to avoid material caking affecting extrusion quality (the screw’s non-cohesive gel design reduces cleaning frequency).
  • Verify the tightness of the take-up device and guide wheel; adjust the tension to prevent conductor damage during operation.

4.2 Regular Maintenance (Every 3 Months/6 Months)

Maintenance Cycle Maintenance Items Operation Requirements Newtopp Support
3 Months Replace the lubricating oil of the screw drive system Use ISO-certified lubricating oil to ensure smooth operation Provide oil type recommendation and maintenance video guidance
3 Months Calibrate the temperature control table and diameter detector Calibrate according to Newtopp’s provided standard parameters Offer online technical support for calibration
6 Months Inspect the die for wear; polish or replace if necessary The die is made of high-hardness alloy, which can be reused after polishing Provide die maintenance tools and replacement parts supply service
6 Months Check the integrated frame structure for looseness Tighten bolts according to torque requirements The equipment frame adopts welding technology from Newtopp’s finishing center, with high structural stability

4.3 Fault Handling Tips

  • Abnormal Temperature Control: Check if the temperature sensor is loose; if the problem persists, contact Newtopp’s technical team .
  • Insufficient Concentricity: Verify the die alignment; refer to the equipment manual or consult Newtopp’s R&D engineers for adjustment methods.
  • Screw Blockage: Stop feeding immediately, heat the barrel to melt the residual material, and clean it .


5. Frequently Asked Questions (FAQ)

Q1: What types of conductors are suitable for the Core Wire Insulation Extrusion Line?

A: The equipment is compatible with copper conductors, aluminum conductors and copper-clad aluminum conductors with a diameter of 0.1mm-2.0mm, which can meet the insulation processing needs of automotive cables, new energy cables, data transmission cables and other products. Newtopp can also provide customized die solutions according to customer-specific conductor specifications, based on its rich experience in cable equipment customization.

Q2: Does the equipment support striped insulation extrusion? How to switch between single-layer and striped modes?

A: Yes, the Core Wire Insulation Extrusion Line supports both single-layer and single-layer+striping insulation extrusion. The switching between modes only requires replacing the corresponding die and adjusting the material feeding parameters through the dedicated touch screen. The equipment’s fast color change design ensures that the mode switching time is controlled within 30 minutes, reducing production downtime. This functional design is derived from Newtopp’s in-depth research on the production needs of multi-type cables.

Q3: How much space can the integrated structure save compared with traditional equipment?

A: The traditional core wire insulation extrusion system requires separate arrangement of accumulator, capstan, take-up, meter counter and other auxiliary devices, with an overall length of about 12-15M. Newtopp’s Core Wire Insulation Extrusion Line integrates all auxiliary functions into one structure, reducing the overall length by more than 5M (the actual length is 7-10M), which greatly saves the factory’s horizontal installation space. This structural optimization is one of the core technological achievements of Newtopp’s R&D center for space-saving equipment.

Q4: What is the service life of the screw in the extrusion line? How to ensure its durability?

A: The screw of the Core Wire Insulation Extrusion Line is made of high-wear-resistant alloy steel and undergoes special heat treatment process, with a service life of more than 30,000 working hours under normal use. Newtopp ensures the screw’s durability through strict raw material selection and precision machining in the finishing center. At the same time, we provide regular screw inspection and maintenance guidance to help customers extend its service life.
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