{"id":28452,"date":"2026-04-26T06:51:50","date_gmt":"2026-04-26T06:51:50","guid":{"rendered":"https:\/\/doingcable.com\/?post_type=product&p=28452"},"modified":"2026-08-07T07:46:33","modified_gmt":"2026-08-07T07:46:33","slug":"insulation-and-sheathing-extrusionproduction-line","status":"publish","type":"product","link":"https:\/\/doingcable.com\/fr\/produit\/insulation-and-sheathing-extrusionproduction-line\/","title":{"rendered":"Ligne de production d'extrusion d'isolant \u00e0 haute vitesse"},"content":{"rendered":"

In today\u2019s competitive global wire and cable market, insulation and sheathing quality directly determines electrical performance, mechanical durability, fire safety compliance and total cost of ownership. The RLB Ligne de production d'extrusion d'isolant \u00e0 haute vitesse<\/strong> (models REK-100, REK-120, REK-150, REK-180) is a robust, technology-driven solution engineered specifically 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.<\/p>\n

This advanced building wire extrusion line and extrusion machine for THHN cables supports conductor cross-sections from 10 mm\u00b2 to 1000 mm\u00b2 and finished diameters up to \u03a6140 mm, with maximum line speeds reaching 180 m\/min. It performs both single-layer insulation and dual-layer (insulation + sheath) processes, including dedicated tandem nylon jacketing for premium THHN\/THWN conductors that dominate North American, European, Canadian and Middle Eastern building-wire markets.<\/p>\n

\"Insulation<\/p>\n

What Is a High Speed Insulation Extrusion Production Line and How Does It Function?<\/h2>\n

A High Speed Insulation Extrusion Production Line continuously coats conductors with insulation materials such as PVC, XLPE (silane or peroxide cross-linkable), PE or Low-Smoke Halogen-Free (LSHF\/HFFR) compounds. The conductor is paid off, optionally preheated, guided through a precision cross-head where molten polymer is extruded under controlled pressure and temperature, then rapidly cooled in multi-pass troughs, diameter-monitored in closed loop, spark-tested, and taken up at synchronized speed. Advanced lines support single-layer, dual-layer (insulation + skin\/stripe) or tandem processes and can incorporate nylon jacketing for THHN\/THWN conductors.<\/p>\n

Core process sequence:<\/p>\n

    \n
  1. Motorized or dual-shaft pay-off with tension control<\/li>\n
  2. Conductor preheater (optional, improves adhesion and reduces voids)<\/li>\n
  3. Main extruder (screw diameters typically \u03a645\u2013\u03a6200 mm, L\/D 25:1\u201326:1) with multi-zone temperature control<\/li>\n
  4. Precision cross-head (center-fed or adjustable) for concentric application<\/li>\n
  5. Multi-pass water cooling trough with air wipe<\/li>\n
  6. Laser diameter gauge + closed-loop feedback to extruder and haul-off<\/li>\n
  7. Spark tester (typically 5\u201315 kV)<\/li>\n
  8. Capstan or caterpillar haul-off<\/li>\n
  9. Automatic dual take-up or coiling system<\/li>\n<\/ol>\n

    \"Sheathing<\/p>\n

    Technical Comparison: High-Speed vs Conventional Insulation Extrusion<\/h3>\n\n\n\n\n\n\n\n\n\n\n\n\n
    Param\u00e8tre<\/th>\nHigh-Speed Insulation Extrusion Line<\/th>\nConventional Extrusion Line<\/th>\n<\/tr>\n<\/thead>\n
    Typical max line speed<\/td>\n350\u20131200 m\/min (small sizes); 45\u2013180 m\/min (large)<\/td>\n50\u2013200 m\/min<\/td>\n<\/tr>\n
    Wall-thickness tolerance<\/td>\n\u00b15 % or better with closed-loop control<\/td>\n\u00b18\u201310 % common<\/td>\n<\/tr>\n
    Concentricity<\/td>\nHigh (European-style cross-heads)<\/td>\nMod\u00e9r\u00e9<\/td>\n<\/tr>\n
    Materials supported<\/td>\nPVC, XLPE, PE, LSHF\/HFFR, Nylon<\/td>\nMainly PVC\/PE<\/td>\n<\/tr>\n
    Syst\u00e8me de contr\u00f4le<\/td>\nPLC + laser feedback closed-loop<\/td>\nOften open-loop<\/td>\n<\/tr>\n
    Scrap rate<\/td>\nLow (real-time adjustment)<\/td>\nPlus haut<\/td>\n<\/tr>\n
    Suitable conductor range<\/td>\n0.5\u20131000 mm\u00b2<\/td>\nLimit\u00e9<\/td>\n<\/tr>\n
    Typical applications<\/td>\nBuilding wire, power, control, THHN<\/td>\nGeneral low-speed production<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

    High-speed lines reduce unit production cost through higher throughput while maintaining dielectric integrity required for modern power and building cables.<\/p>\n

    Core Technology & Process Advantages<\/h3>\n

    Flexible Material Compatibility<\/strong><\/p>\n

    Optimized screw geometry and multi-zone temperature control ensure excellent melt homogeneity for PVC (cost-effective processing), XLPE (90\u2013110\u00b0C heat resistance plus moisture\/chemical protection), PE and LSHF\/HFFR compounds, minimizing scorch risk and supporting consistent crosslinking when required.<\/p>\n

    Intelligent Closed-Loop Automation<\/strong><\/p>\n

    Mitsubishi PLC + MMI system with real-time laser diameter feedback automatically adjusts extruder output and line speed. This closed-loop control reduces scrap, maintains tight dimensional tolerances and ensures consistent compliance with UL 83, IEC 60502 and GB standards \u2014 a key differentiator versus conventional open-loop lines.<\/p>\n

    THHN-Specific Tandem Extrusion<\/strong><\/p>\n

    Dedicated configuration applies PVC insulation and Nylon (PA) outer jacket in a single continuous pass. The result is superior abrasion resistance, chemical protection and low-friction conduit performance while eliminating intermediate handling steps and improving overall productivity.<\/p>\n

    Complete Auxiliary Integration<\/strong><\/p>\n

    On-line aluminum strip longitudinal taping, asphalt\/graphite coating, automatic feeding, granule dryers, color masterbatch metering, laser\/ink printers, spark testers, diameter gauges and stamping machines create a true turnkey production system.<\/p>\n

    Configurable Layout Flexibility<\/strong><\/p>\n

    Multiple pay-off and take-up options (drum, coil or dual) minimize downtime and allow seamless integration with existing upstream drawing\/stranding lines or downstream armoring and jacketing equipment.<\/p>\n

    \"Machines<\/p>\n

    Typical Technical Parameters of Current High-Speed Lines<\/h3>\n\n\n\n\n\n\n\n\n\n\n
    Model \/ Screw Config<\/th>\nConductor Cross-Section<\/th>\nFinished OD (approx.)<\/th>\nMax Line Speed<\/th>\nMax Extrusion Output (PVC)<\/th>\nApplications typiques<\/th>\n<\/tr>\n<\/thead>\n
    70\/45 or 80\/45<\/td>\n0.5\u201310 mm\u00b2<\/td>\n1.9\u20137.6 mm<\/td>\nup to 350 m\/min<\/td>\n150\u2013230 kg\/h<\/td>\nBuilding wire, flexible cable<\/td>\n<\/tr>\n
    REK-100 \/ \u03a6100<\/td>\n10\u2013240 mm\u00b2<\/td>\nup to 45 mm<\/td>\n180 m\/min<\/td>\n\u2014<\/td>\nSmall power & building cables<\/td>\n<\/tr>\n
    REK-120 \/ \u03a6120<\/td>\n25\u2013630 mm\u00b2<\/td>\nup to 80 mm<\/td>\n150 m\/min<\/td>\n\u2014<\/td>\nMedium power cables<\/td>\n<\/tr>\n
    REK-150 \/ \u03a6150<\/td>\n50\u2013800 mm\u00b2<\/td>\nup to 100 mm<\/td>\n60 m\/min<\/td>\n\u2014<\/td>\nPower & control cables<\/td>\n<\/tr>\n
    REK-180 \/ \u03a6180<\/td>\n120\u20131000 mm\u00b2<\/td>\nup to 140 mm<\/td>\n45 m\/min<\/td>\n\u2014<\/td>\nLarge power cables<\/td>\n<\/tr>\n
    Fine-wire high-speed<\/td>\n<0.5 mm diameter<\/td>\n\u2014<\/td>\n500\u20132000 m\/min<\/td>\nlower<\/td>\nMagnet wire, automotive, data<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

    Screw L\/D ratios of 25:1\u201326:1, multi-zone heating, and optimized screw geometry ensure melt homogeneity and minimize scorch risk for heat-sensitive compounds such as XLPE and LSHF.<\/p>\n

    \"High<\/p>\n

    Principales applications dans la fabrication de c\u00e2bles<\/h3>\n