In high-voltage, extra-high-voltage, submarine, and chemically aggressive environments, the lead sheath remains the ultimate radial moisture barrier, providing decades of reliable protection against water ingress, oil penetration, corrosion, and mechanical damage. The RLB Continuous Lead Extrusion Line (models 100/5, 150/5, 200/5) is a factory-direct Continuous Extrusion Machine that applies seamless, high-purity lead cladding with superior concentricity, uniform wall thickness, and flawless surface quality.
As a competitive-price continuous lead extrusion machine factory, RLB combines proven European-level horizontal lead extrusion technology with robust, synchronized system design — ensuring stable material flow under strictly controlled constant temperature, constant speed, and constant pressure conditions for defect-free sheathing.
Lead remains the preferred material for the most demanding environments because of its proven corrosion resistance (especially in marine and chemical settings), impermeability to water and oils, and ability to maintain integrity under high electrical stress for decades.
Core Technology & Engineering Advantages of This Continuous Lead Extruding Line
- Complete Synchronized Production System: Lead ingot feeding with melting/holding furnaces, Ω-shaped output tube for stable flow, high-precision extrusion unit, gearbox, water-cooling tank, screw & nut assembly, and die holder — all engineered for continuous, high-efficiency operation.
- Advanced Process Control: Intelligent MMI + PLC system delivers full-line synchronization, real-time monitoring, recipe storage, and instant parameter adjustment for repeatable, high-quality lead sheathing.
- Robust Supporting Systems: Gantry-type pay-off and take-up units with cable tray support, advanced gear lubrication, and circulating cooling water systems minimize downtime and maximize throughput.
- Versatile Dual Capability: Ideal for continuous lead sheathing of cable cores and lead vulcanization (sulfidation) of rubber tubes — offering exceptional flexibility for specialty cable producers.
- Superior Sheath Quality: Maintains constant process parameters to eliminate thickness variation, porosity, or surface imperfections — delivering homogeneous, ductile lead sheaths that provide superior flexibility, fault-current capacity, and long-term durability.
This wire extruder machine and extrusion production line solution ensures compliance with international standards for critical HV/EHV and submarine applications while delivering measurable gains in output quality and operational cost savings.
Technical Specifications
| Model | Core Wire Diameter (mm) | Cladding Diameter (mm) | Screw Speed (rpm) | Line Speed (m/min) | Heating Power (kW) |
|---|
| 100/5 | Φ5–35 | Φ6–45 | 2–13.5 | 3–26 | 128 |
| 150/5 | Φ20–100 | Φ20–105 | 2–13 | 2.5–27 | 145 |
| 200/5 | Φ55–132 | Φ60–140 | 2–13 | 2.5–20 | 240 |
Typical system composition
Lead ingot feeding mechanism → Melting furnace → Holding furnace → Ω-shaped lead output tube → High-precision extrusion unit (screw & nut) → Gearbox & water-cooling tank → Die holder → Circulating cooling system → Gantry-type pay-off & take-up with cable tray support → Advanced MMI + PLC control system with gear lubrication.
Output capacity is alloy-dependent (pure lead, soft alloys such as E or ½C, or harder alloys). Advanced horizontal designs achieve outputs in the range of 15–55 kg/min depending on machine type and alloy, with die blocks covering diameters from approximately 6 mm up to 190–225 mm.
Process Highlights
- Solid lead ingots are automatically fed into electrically heated melting and holding furnaces (typically 10–60 ton capacity options).
- Molten lead flows through a precisely temperature-controlled Ω-tube into the extrusion unit.
- The screw-type extruder forces the lead under controlled pressure through the die block, forming a seamless tube around the continuously advancing cable core.
- Immediate controlled cooling stabilizes the sheath dimensions and metallurgy.
- Full-line PLC synchronization maintains constant speed and tension, ensuring uniform thickness and concentricity over multi-kilometer production runs.
Strict control of extrusion temperature, cooling zones and die design is critical for large-diameter EHV and submarine cables, where outer-diameter uniformity (often within 0.2 mm) and thickness stability are essential for subsequent armor and service performance.
Primary Applications in HV/EHV Cable Industry
- Power Cable Lead Sheathing: High-voltage (HV) and extra-high-voltage (EHV) cables requiring long-term moisture and corrosion protection
- Submarine & Offshore Cables: Ultimate radial water barrier for underwater transmission lines
- Oil-Filled Cables: Reliable oil containment and pressure resistance
- Rubber Tube Lead Vulcanization: Continuous lead cladding/sulfidation of specialty rubber hoses and tubes
- Specialty Cables: Harsh industrial, marine, chemical, or petrochemical environments
Compared to aluminum sheaths, lead provides superior corrosion resistance (especially in coastal/marine settings) and proven longevity — with failure rates over 6 times lower in long-term field data.
Why Partner With a Specialist Supplier
As a technology-driven manufacturer focused on reliable quality and customized technical solutions, we deliver complete continuous lead extrusion systems engineered for 24/7 industrial operation. Every line is designed for:
- High first-pass yield and minimal scrap
- Easy maintenance and long component life
- Seamless integration with existing pay-off, take-up and quality-control equipment
- Full technical support, process recipes and operator training
We emphasize long-term cooperation: from initial capacity planning and alloy selection through installation, commissioning and ongoing process optimization. Our engineering team works closely with customers to match exact cable diameter ranges, production volumes and quality targets.
Ready to upgrade your HV/EHV lead sheathing capability?
Contact our technical sales team for detailed layout drawings, capacity calculations, alloy recommendations and a customized quotation.
Inquiry Now – Share your target cable diameter range, annual production volume and preferred alloy. We will respond with a tailored technical proposal within 24–48 hours.
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