INSULATION · SHEATHING · XLPE

Cable Compound and XLPE Production Lines

Twin-screw and two-stage systems for cable insulation, sheathing, crosslinkable polyethylene and low-smoke compounds.

Processing challenge

Cable formulations can be highly filled, heat-sensitive or reactive. They require controlled mixing, limited thermal history, effective venting and stable pelletizing.

Recommended equipment approach

The catalogue identifies SHJ two-stage systems for heat- and shear-sensitive compounds and tandem lines for crosslinkable polyethylene. SJSH or DY systems may be selected for other cable compound duties.

Typical materials

PVC cable compounds
PE cable insulation and sheathing
XLPE compounds
Low-smoke, low-halogen formulations
EVA and carbon-black-containing materials

Pelletizing and downstream

Air-cooled hot-face or other low-water-contact arrangements may be appropriate for water-sensitive materials. Final selection depends on formulation.

Information required for quotation

Polymer and crosslinking system
Filler and carbon-black content
Target output
Required pellet moisture and cleanliness
Voltage, automation and packaging requirements

Line layouts

XLPE cable compound, tandem line

PE resin, antioxidant and DCP are dosed by loss-in-weight feeder and pump into the twin-screw extruder, then transferred to a single-screw extruder and cut by an eccentric fog-jetting cutter. The low-pressure, short-channel die and low-temperature mixing are what prevent premature crosslinking.

Flow diagram of a tandem line producing crosslinkable polyethylene cable compound with loss-in-weight dosing and eccentric fog-jetting pelletizing — 1 PE resin silo, 2 antioxidant silo, 3 DCP tank, 4 loss-in-weight feeder, 5 loss-in-weight pump, 6 twin-screw extruder, 7 single-screw extruder, 8 eccentric cutter, 9 fan, 10 fluidising bed, 11 product container, 12 automatic bagging.

Low-smoke halogen-free and PVC cable compound, SHJ tandem line

For PVC cable compound, low-smoke zero-halogen material and EVA shielding compound, the SHJ tandem line with air-cooled hot-face cutting keeps melt temperature and shear low through the pelletizing stage.

Flow diagram of an SHJ tandem line for compounding and air-cooled hot-face pelletizing of cable compound — 1 metering feeder, 2 cramming feeder, 3 twin-screw extruder, 4 single-screw extruder, 5 hot-face cutter with air cooling, 6 cyclone, 7 fluidising bed.

Flame-retardant compound via Banbury mixer

Where aluminium hydroxide or magnesium hydroxide loadings are very high, a Banbury mixer feeding an extruder with eccentric fog-jetting pelletizing handles the filler content that a single compounding pass would struggle with.

Flow diagram of a Banbury mixer with extruder and eccentric fog-jetting pelletizer for flame-retardant cable compound

Compound	50/120	65/150	75/180	95/200
PVC cable, low-smoke zero-halogen, transparent and medical-grade, shoe sole	150–300	250–500	350–800	700–1100
PE peroxide and silane crosslinked cable, crosslinked piping, PE and EVA shielding	120–250	200–450	280–600	800–1400

Output in kg/h, catalog reference values — confirmed against your formulation.