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 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 et 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 is not merely a manufacturing step — it is the foundation of cable performance and total cost of ownership:
- Dielectric strength & long-term electrical reliability — uniform wall thickness and superior concentricity eliminate weak spots that cause partial discharge, especially critical in medium-voltage and high-performance building wires.
- Mechanical protection — consistent coverage resists abrasion, impact, crushing and environmental stress cracking throughout the cable’s service life.
- Fire performance — precise application of LSHF/HFFR and XLPE compounds ensures flame retardancy, low smoke and halogen-free properties demanded by modern building codes and infrastructure projects.
- Installation efficiency — smooth, low-friction nylon jackets on THHN/THWN conductors dramatically reduce pulling force through conduit, lowering labor costs on-site.
- Reduced total cost of ownership — lower scrap rates, higher throughput and fewer field failures translate directly into measurable ROI.
RLB’s closed-loop automation and optimized screw designs guarantee uniform wall thickness (±5% tolerance), outstanding concentricity and repeatable quality even across high-volume 24/7 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.
Spécifications techniques
| Modèle | 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.
Principales applications dans la fabrication de câbles
- Câbles d'alimentation — Low-, medium- and high-voltage cables requiring XLPE or LSHF insulation and sheathing for excellent electrical performance and fire safety in infrastructure, utility and industrial projects.
- 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 fast, low-friction conduit installation.
- Câbles de commande et d'instrumentation — Precise, concentric insulation and sheathing for reliable signal transmission in demanding industrial environments.
- Câbles de télécommunication et de données — High-quality PE or LSHF compounds for LAN, telephone and data cables where low attenuation and fire performance are critical.
- Câbles spéciaux — 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?
Demande d'informations 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.
Foire aux 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 steps and improving overall productivity.
How does closed-loop control improve quality and reduce costs?
Real-time laser diameter measurement feeds back to the PLC, automatically adjusting extruder output and line speed to maintain tight tolerances on wall thickness and concentricity. This dramatically reduces scrap, ensures consistent compliance with UL, IEC and GB standards, and improves overall equipment effectiveness (OEE).
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. Custom compliance packages are available.
Can the line be integrated with existing cable production equipment?
Yes. The modular design and configurable pay-off/take-up options allow seamless integration with upstream stranding or drawing lines and downstream armoring, jacketing or coiling systems. Our engineers provide full layout and interface support.
What after-sales support and ROI can I expect?
RLB provides installation supervision, commissioning, operator training, spare parts and long-term technical service. Customers typically achieve faster ROI through higher throughput, lower scrap rates, reduced energy consumption and reliable 24/7 operation.
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