Product Overview

At its core is a precision extruder (φ65 mm with 30:1 L/D ratio) optimized for processing diverse sheath materials, from PVC and PE to LSZH (low smoke zero halogen) compounds and nylon. The multi-layer die enables co-extrusion of insulation and jacket in a single pass, reducing production steps while ensuring perfect adhesion between layers. With a PLC-controlled tension system (±1% accuracy) and high-speed haul-off (up to 200 m/min), this line handles 0.5-6.0 mm wire diameters with exceptional precision, minimizing material waste by 15% compared to conventional sheathing lines. Whether producing fire-resistant cables for buildings, flexible cords for appliances, or ruggedized cables for industrial machinery, this system ensures consistent quality, high productivity, and compliance with global standards.

Product Specifications

Process Technology

Material Compatibility: Processes PVC (flexible and rigid), PE (LDPE, HDPE), LSZH compounds, and nylon (PA6, PA12), complying with UL 1581, IEC 60332-1-2, and RoHS 2.0 standards. Supports material-specific processing parameters stored in the PLC.

Extrusion System: φ65 mm single-screw extruder with grooved feed section for improved material feeding and a barrier screw design for uniform melting. Delivers 150-300 kg/h output with stable melt pressure (5-15 MPa).

Die Design: Coaxial die enabling insulation+jacket co-extrusion with adjustable concentricity (±0.02 mm via precision micrometers). Die lips are chrome-plated for wear resistance and easy cleaning.

Mechanical Design

Payoff Unit: Automatic reel changer accommodating 36-60 inches diameter reels, equipped with a magnetic powder brake for ±1% tension control (5-500 N range). Supports uninterrupted production with automatic reel switching.

Cooling System: Water spray + air cooling station with adjustable water flow (5-20 L/min) and air pressure (0.2-0.5 MPa), reducing sheath temperature from extrusion temperature to ≤50°C to ensure dimensional stability.

Cutting System: Hydraulic flying saw with CNC-controlled positioning (±0.5 mm accuracy) for cut-to-length production, with optional spooling unit for continuous winding.

Control System

PLC+HMI Interface: 12-inch touchscreen displaying real-time monitoring of die pressure (0-20 MPa), line speed (5-200 m/min), and jacket thickness (via laser micrometer, ±0.01 mm). Stores 50+ production recipes for quick changeover.

Safety Features: Emergency stop buttons at all operator stations, over-temperature protection (≥250°C shutdown), and material flow interruption detection with automatic alarm and shutdown.

Applications

Power Cables

Manufactures LSZH jackets for fire-resistant power cables used in high-rise buildings, tunnels, and public transport, meeting BS 6724 and EN 50265-2-1 for low smoke emission and flame spread.

Produces PE jackets for medium-voltage cables, providing moisture resistance (IEC 60811-403) and UV protection for outdoor installations.

Telecom Wires

Processes PE and LSZH jackets for fiber optic cables, ensuring low dielectric loss (≤0.001 at 1 GHz) and crush resistance (≥10 kN/m) to protect delicate fibers.

Manufactures armored telecom cables with steel or aluminum tape reinforcement, providing rodent and mechanical protection for underground installations.

Automotive Harnesses

Produces PVC and TPE jackets for automotive wires and harnesses, complying with ISO 6722-1 (Class A/B) and VW LV 216 for temperature resistance (-40°C to 125°C) and oil resistance.

Supports multi-core cable sheathing for automotive infotainment and sensor systems, with precise dimensional control for connector fitting.

Industrial Cables

Creates nylon and PU jackets for robotic and automation cables, with 10 million bend cycles durability (ASTM D2176, 10× cable diameter bend radius) and resistance to industrial oils.

Manufactures heat-resistant silicone jackets for high-temperature industrial cables, rated for continuous operation at 180°C (UL 1581 VW-1 flame rating).

FAQ

Q: What is the maximum wire diameter this line can handle?

A: It accommodates 6.0 mm for single-core wires and 12.0 mm for multi-core cables, with customizable payoff and haul-off units available for larger diameters up to 16 mm.

Q: Can it integrate with existing stranding machines?

A: Yes, its universal capstan interface with adjustable speed synchronization (via encoder feedback) supports seamless integration with most stranding machines handling 1.0-6.0 mm wire diameters. Tension control is coordinated with upstream processes to prevent wire stretching.

Q: What certifications does the sheathing line hold?

A: The line itself complies with CE (Machinery Directive 2006/42/EC) and ISO 9001:2015. Produced cables meet UL 62 (electrical insulation), IEC 60332-1-2 (flame test), and RoHS 2.0 (restricted substances), with additional certifications available based on material selection.

Q: How does it ensure uniform jacket thickness across long production runs?

A: The system uses a closed-loop control system that continuously measures jacket thickness via laser micrometers (100 measurements/second) and adjusts the extruder speed and die position in real-time, maintaining thickness tolerance within ±5% of nominal value—exceeding industry standards.