Product Overview

Its 200mm high-torque screw with 25:1 long processes high-viscosity materials (XLPE, silicone rubber, EPR) at output rates of up to 1,200 kg/h, making it suitable for submarine cables, mining cables, and high-voltage power cables. The line’s modular design allows customization with options like water-blocking tape applicators and armor layer integration, while its multi-zone temperature control (12 heating zones) ensures uniform melting, critical for XLPE cross-linking. A water-cooled barrel prevents overheating during 24/7 operation, maintaining consistent material viscosity.

Product Specifications

Maximum Output: 1,200 kg/h (HDPE) / 900 kg/h (XLPE) / 700 kg/h (Silicone)

Material Compatibility: XLPE, Silicone rubber, EPR (ethylene propylene rubber), HDPE, PP

Power Consumption: 600 kW (with regenerative braking for energy recovery)

Control System: Allen-Bradley ControlLogix PLC with SCADA integration; remote monitoring via cloud platform

Die Head Type: Crosshead die for large-diameter cables (up to 150mm) with laser alignment (±0.05mm)

Cooling System: Water jacket with chilled water circulation (5–25°C) and temperature feedback control

Applications

Submarine Cables:

Produces waterproof XLPE insulation for submarine power cables (110kV–500kV), compliant with IEC 60502-6 (water tightness) and IEEE 488 (pressure testing: up to 100 bar). Integrates with lead or aluminum sheathing for corrosion resistance.

Mining Cables:

Processes flame-resistant EPR insulation for underground mining cables, withstanding mechanical abuse (impact, crushing) and meeting IEC 60092-354 (flame propagation index ≤25).

High-Voltage Cables:

Extrudes XLPE insulation for 110kV–500kV power transmission cables, ensuring dielectric strength ≥40 kV/mm and thermal stability (90°C continuous operation).

Industrial Pipes:

Converts HDPE into large-diameter pipes (200–630mm) for water and gas transmission, meeting ASTM D3035 (hydrostatic pressure: 100 bar for 10,000 hours) and ISO 4427 (dimensional tolerance).

FAQ

Q: What size range of cables can this line process?

A: It handles cables from 20mm to 150mm in diameter, with custom tooling available for larger sizes up to 200mm.

Q: Is it capable of processing recycled XLPE materials?

A: Yes, with its high-shear mixing section, it can incorporate up to 30% post-consumer recycled XLPE while maintaining mechanical and electrical properties.

Q: How is precision maintained for large-diameter cables?

A: The die head uses laser alignment technology paired with ultrasonic thickness sensors, ensuring concentricity within ±0.05mm across the cable circumference.

Q: What safety features protect operators and equipment?

It includes overspeed protection (motor speed ≥110% of setpoint triggers shutdown), temperature alarms (±10°C deviation from setpoint), and redundant emergency stop systems with hardwired safety relays.