In the competitive wire and cable industry, the insulation and sheathing stage is decisive for achieving superior electrical performance, mechanical strength, fire safety, and decades of reliable service life. The Insulation and Sheathing Extrusion Production Line (models REK-100, REK-120, REK-150, REK-180) is an advanced building wire extrusion line engineered for high-precision extrusion of PVC, PE, XLPE, and Low Smoke Halogen-Free (LSHF/HFFR) compounds onto power cables, building wires, control cables, and telephone lines.
This robust extrusion machine for THHN cables and extrusion machine for THHN wires supports conductor cross-sections from 10–1000 mm² and finished diameters up to Φ140 mm, with maximum line speeds reaching 180 m/min. It excels in both single-layer insulation and dual-layer (insulation + sheath) processes, including tandem nylon jacketing for premium THHN/THWN conductors.
Why Precision Insulation & Sheathing Matters
High-quality extrusion directly impacts:
- Dielectric strength and long-term electrical reliability
- Mechanical protection against abrasion, impact and environmental stress
- Fire performance (flame retardancy, low smoke, halogen-free properties)
- Ease of installation (low-friction nylon jackets for THHN conduit pulling)
- Overall cable lifespan and total cost of ownership
RLB’s closed-loop automation and optimized screw designs ensure uniform wall thickness, superior concentricity and repeatable quality across high-volume production runs.
Advanced Features & Process Control
Flexible Material Compatibility: Optimized screw geometry and multi-zone temperature control deliver excellent melt homogeneity for PVC (cost-effective, easy processing), XLPE (superior heat resistance 90–110°C, moisture/chemical resistance), PE, and LSHF/HFFR compounds — minimizing scorch risk and ensuring consistent crosslinking where required.
- Intelligent Automation & Closed-Loop Control: Mitsubishi PLC + MMI system with real-time laser diameter feedback guarantees outstanding concentricity, uniform wall thickness (±5% tolerance), and repeatable quality — critical for meeting strict UL 83, IEC 60502, and GB standards.
- THHN-Specific Tandem Extrusion Capability: Dedicated configuration for PVC insulation + Nylon (PA) outer jacket in a single pass, delivering the abrasion resistance, low-friction conduit pulling, and chemical protection demanded by modern THHN/THWN building wires.
- Comprehensive Auxiliary Integration: On-line aluminum strip taping, asphalt/graphite coating, automatic feeding, granule dryers, color masterbatch metering, laser/ink printers, spark testers, diameter gauges, and stamping machines for full turnkey operation.
- Configurable Downstream Flexibility: Multiple pay-off/take-up options (drum, coil, dual) ensure minimal downtime and seamless integration with your existing building wire extrusion line layout.
The result is cables with smooth surface finish, outstanding electrical properties, and full compliance with international standards — produced with maximum throughput and minimum material waste.
Technical Specifications
| Model | Conductor Cross Section | Finished Diameter | Max. Line Speed | Typical Applications |
|---|
| REK-100 | 10 – 240 mm² | Up to 45 mm | 180 m/min | Building wires, small power cables |
| REK-120 | 25 – 630 mm² | Up to 80 mm | 150 m/min | Medium building & power cables |
| REK-150 | 50 – 800 mm² | Up to 100 mm | 60 m/min | Power cables, control cables |
| REK-180 | 120 – 1000 mm² | Up to 140 mm | 45 m/min | Large power cables, specialty cables |
Notes: Custom configurations, higher-capacity models and specialized XLPE crosslinking (steam or silane) systems available upon request. Line speed depends on compound, wall thickness and cooling requirements.
Primary Applications in Cable Manufacturing
Power Cables Low-, medium- and high-voltage cables requiring XLPE or LSHF insulation and sheathing for excellent electrical and fire performance.
Building & Installation Wires PVC-insulated and sheathed cables (BV, BVV, NYY) and premium THHN/THWN conductors with tandem nylon jacketing for superior abrasion resistance and installation ease.
Control & Instrumentation Cables Precise, concentric insulation and sheathing for reliable signal transmission in industrial environments.
Telecommunication & Data Cables High-quality PE or LSHF compounds for LAN, telephone and data cables.
Specialty Cables Flame-retardant, fire-resistant and low-smoke halogen-free constructions meeting the most demanding international fire safety standards.
Engineered for Reliability, Efficiency & Long-Term ROI
Manufactured by RLB (Jiangsu Reliable Industry Co., Ltd.) — a proven specialist in wire and cable machinery — every component of this Insulation and Sheathing Extrusion Production Line is built for 24/7 continuous operation with minimal maintenance.
Compared with conventional extrusion lines, the RLB solution delivers:
- Superior concentricity and wall thickness uniformity (±5 % tolerance)
- Significantly reduced scrap rates through closed-loop laser diameter control
- Lower operating costs via energy-efficient material processing and high line speeds
- Full compliance with IEC 60502, UL 83, BS and customer-specific requirements
- Seamless integration with upstream conductor drawing/stranding lines and downstream armoring or jacketing equipment
Whether you produce standard PVC building wires or high-performance XLPE, LSHF or THHN/THWN cables, this cable extruder machine provides the technical reliability, production flexibility and long-term partnership modern cable manufacturers demand.
Built for Global Standards & Turnkey Partnership
RLB offers complete turnkey solutions including engineering design, equipment supply, installation supervision, commissioning, operator training and ongoing technical support. Custom configurations are available to match your exact conductor range, compound types, line speed targets and factory layout requirements.
With proven technology, robust construction and comprehensive after-sales service, the RLB Insulation and Sheathing Extrusion Production Line represents a reliable, high-ROI investment for cable producers worldwide.
Ready to elevate your insulation and sheathing production quality and efficiency?
Inquiry Now for a detailed technical quotation, custom configuration options, layout design recommendations or factory visit arrangement. Our engineering team provides complete turnkey solutions, installation support, operator training and long-term technical partnership tailored to your production goals.
Frequently Asked Questions
What materials can the RLB Insulation and Sheathing Extrusion Production Line process?
The line is optimized for PVC, PE, XLPE and Low Smoke Halogen-Free (LSHF/HFFR) compounds. Dedicated tandem configurations also support Nylon (PA) jacketing for THHN/THWN wires.
What is the advantage of tandem extrusion for THHN/THWN cables?
Tandem extrusion applies PVC insulation and Nylon outer jacket in a single continuous pass, delivering superior abrasion resistance, chemical protection and low-friction properties required for easy conduit pulling while reducing handling and improving productivity.
How does closed-loop control improve quality?
Real-time laser diameter measurement feeds back to the PLC, automatically adjusting extruder output to maintain tight tolerances on wall thickness and concentricity — dramatically reducing scrap and ensuring consistent compliance with UL, IEC and GB standards.
What standards does the line support?
The equipment is designed to produce cables meeting or exceeding UL 83 (THHN/THWN), IEC 60502 (power cables), BS standards and GB/T requirements for building wires and power cables.
Can the line be integrated with existing cable production equipment?
Yes. RLB specializes in turnkey solutions and can configure pay-off/take-up systems, auxiliary equipment and control interfaces to integrate seamlessly with your existing drawing, stranding or armoring lines.
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