Wire & Cable Extrusion Line
High-Performance Wire & Cable Extruder for Precision Insulation
Engineered for stable wire diameter control, superior core concentricity and maximum energy efficiency. Trusted by 3,500+ global manufacturers for PVC, PE, XLPE and HFFR cable production.
CE & ISO Certified
24-Month Core Warranty
24/7 Engineer Support
±0.01mm Diameter Tolerance
[ Main Extruder Machine Image ]
99.5% Core Concentricity
12%Scrap Reduction
±0.5℃Temp Uniformity
30%+Energy Saved
99.5%Core Concentricity
Engineering Advantages
Solving Critical Cable Extrusion Challenges
Standard machines often fail on complex polymer rheology. UET extruders are precision-engineered to eliminate diameter deviation, prevent material degradation and guarantee flawless concentricity.
Precision Wire Diameter Control
Smart PLC temperature control and precision die fine-tuning hold tolerances to ≤±0.01mm, raising your factory qualification rate and cutting material waste.
Optimized Core Concentricity
Optimized positioning mechanisms, rigid machine bases and stable melt pressure guarantee exceptional concentricity for power and data cables.
Multi-Material Compatibility
Switch seamlessly between PVC, PE, XLPE and LSZH/HFFR. Customized screw geometries ensure optimal plasticization without frequent re-adjustment.
Energy & Cost Efficiency
High-torque energy-saving drives and optimized barrel heating zones cut unit energy consumption by over 30% for eco-friendly, cost-conscious production.
Simplified Maintenance
Quick mold changes (≤12 min) and easy access to wear parts. Modular structure minimizes downtime and lowers the skill threshold for operators.
Stable 24/7 Operation
Bimetallic barrels and wear-resistant screws deliver stable output and consistent quality through long, uninterrupted heavy-duty production runs.
Turnkey Line Layout
Complete Cable Extrusion Line Process
We configure the entire synchronized line — from pay-off to take-up — for maximum throughput, precise tension control and flawless insulation application.
1
Active Pay-off
Motorized dual-spool payoff with precise tension control to prevent conductor stretching.
[ Pay-off Stand Image ]
2
Extruder & Crosshead
Precision melting and uniform coating through a self-centering extrusion crosshead die.
[ Extruder & Crosshead Image ]
3
Cooling Trough
Multi-zone water cooling solidifies insulation gradually, avoiding thermal shock.
[ Cooling Trough Image ]
4
Precision Capstan
Belt/wheel capstan closed-loop synchronized with screw RPM for constant line speed.
[ Capstan Image ]
5
Dual Take-up
Automatic dual-spool take-up with non-stop wire exchange for continuous runs.
[ Take-up Image ]
Material Rheology Expertise
Advanced Material Processing Capabilities
Every cable compound demands a specific thermal and shear profile. UET customizes screw geometry and barrel configuration to your exact formula.
Thermoplastic Insulation
Challenge
PVC releases corrosive HCL gas if overheated; PE demands excellent melt homogeneity for thin-wall insulation.
UET Solution
Corrosion-resistant bimetallic barrels with low-shear screws and precise thermal profiling for degradation-free plasticization.
Cross-Linked Polyethylene
Challenge
High risk of premature cross-linking (“scorch”) causes die buildup and catastrophic surface defects on HV cables.
UET Solution
Water-cooled feed throats, low-compression screws and polished flow channels eliminate dead spots for smooth continuous runs.
Low-Smoke Zero-Halogen
Challenge
Heavy mineral filler loads (ATH) require immense torque and aggressive mixing for even dispersion.
UET Solution
High-torque gearboxes with Maddock/pineapple distributive mixing elements guarantee uniform filler dispersion and strength.
In-House Manufacturing
Core Components Engineering
Reliability is defined by internal engineering. We machine the critical components in-house to guarantee uncompromised precision.
[ Extruder Screw & Barrel Image ]
Component 01
Nitride & Bimetallic Screw / Barrel
The heart of extrusion. Our screws undergo 72-hour nitriding or carry bimetallic alloy linings reaching HV 950+ surface hardness — superior wear resistance against abrasive HFFR compounds, extending core component life up to 3× versus standard steel.
[ Extrusion Crosshead Die Image ]
Component 02
Precision Extrusion Crosshead
A poor crosshead causes eccentricity and waste. UET crossheads use a self-centering die mechanism and optimized flow-channel geometry to guarantee perfectly concentric insulation — critical for electrical safety and cable longevity.
Models & Parameters
Typical Configurations & Technical Specifications
From compact data-cable lines to heavy-duty tandem HV lines — we engineer the exact setup your product demands.
Building Wire Line (UET-65)
High-speed extrusion of standard PVC/PE building wires with rapid heating zones and high-output screws.
- Max Output: 220 kg/h
- Line Speed: up to 800 m/min
- Best for: THHN, BV, RV wires
XLPE Power Cable Line (UET-85)
Low-screw-shear design with precise thermal control for sensitive MV/HV XLPE compounds — zero scorch.
- Max Output: 500 kg/h
- Screw: low-compression design
- Best for: MV/HV insulation
Multi-Layer Co-Extrusion Line
PLC-synchronized tandem extruders apply inner semi-con, insulation and outer semi-con in a single pass.
- Config: 1+2 / 2+1 tandem
- Control: Siemens S7 PLC
- Best for: specialty power cables
| Model | Screw Dia. (mm) | L/D Ratio | Output (kg/h) | Main Motor | Primary Application |
|---|---|---|---|---|---|
| UET-55 | 55 | 24:1 / 26:1 | 80–120 | 18 HP (15 kW) | Small wires, telecom & data cables |
| UET-65 | 65 | 24:1 / 28:1 | 150–220 | 30 HP (22 kW) | Building wires, control cables |
| UET-75 | 75 | 26:1 / 30:1 | 250–350 | 45 HP (35 kW) | Medium power cables, automotive wire |
| UET-85 | 85 | 26:1 / 30:1 | 380–500 | 60 HP (45 kW) | Large cables, XLPE insulation |
| UET-95 | 95 | 28:1 / 32:1 | 550–750 | 80 HP (60 kW) | HV cables, heavy sheathing, HFFR |
Field Engineering Support
Troubleshooting Common Extrusion Defects
Actionable solutions from our application engineers for the defects that cost cable factories the most money.
DefectSharkskin / Melt Fracture (Surface Roughness)
Cause: Excessive shear stress at the die exit tears the melt surface microscopically — common in LLDPE and mPE.
UET Solution
Raise die exit temperature, optimize die land length or add a polymer processing aid (PPA). UET dies are mirror-polished with optimized geometry to lower shear stress inherently.
DefectEccentricity (Off-Center Insulation)
Cause: Uneven melt pressure in the crosshead, improper die centering or fluctuating traction speed pulling the wire off-center.
UET Solution
Self-centering crosshead dies with precision adjustment bolts, uniform barrel heating zones, and closed-loop PLC synchronization of capstan speed with screw RPM.
DefectBlisters / Porosity in Insulation
Cause: Trapped moisture, volatiles or air bubbles expanding as the melt exits the high-pressure die.
UET Solution
Hopper dryers for hygroscopic materials plus atmospheric/vacuum venting zones on the barrel to extract gases before the melt reaches the die.
DefectPremature Cross-Linking (Scorch) in XLPE
Cause: Material cures inside the barrel or die head instead of on the wire — lumps, die buildup and line stoppage follow.
UET Solution
Water-cooled feed throats block backward heat conduction; low-compression screws and polished flow channels eliminate dead spots where material lingers and cures.
20+ Years · 80+ Countries
Why Global Manufacturers Choose UET
5,600+ successful installations and two decades of continuous extrusion R&D behind every line we ship.
Custom Engineering & OEM
Custom L/D ratios, screw geometries and co-extrusion setups tailored to your factory layout, materials and output goals.
24/7 Global Support
Rapid-response maintenance, operator training and lifetime technical consulting keep your line running on every continent.
CE / ISO Certified Quality
Precision grinding and nitriding on every screw and barrel; full CE/ISO compliance for safety and smooth customs clearance.
Fast Return on Investment
Lower scrap, lower energy, less downtime — a UET line typically pays for itself within 18 months of operation.
Technical FAQ
Wire & Cable Extrusion: Frequently Asked Questions
What is the difference between pressure tooling and tubing tooling in cable crossheads?
Pressure tooling applies melt under high pressure directly onto the conductor at the die tip, creating a tight void-free bond — ideal for high-voltage cables requiring strict electrical integrity. Tubing tooling extrudes a loose tube first, then draws it down onto the wire via vacuum or tension — easier concentricity adjustment, typically used for standard jacketing and low-voltage insulation.
How do screw L/D ratio and compression ratio affect HFFR (LSZH) compounding?
HFFR compounds carry up to 60% mineral filler (ATH), making them viscous and hard to process. A standard 24:1 L/D often lacks residence time for dispersion. UET recommends 28:1–32:1 L/D with a lower compression ratio (2.0–2.5:1) — preventing excessive shear heat while distributing heavy fillers uniformly to preserve flame-retardant properties.
Why is a water-cooled feed throat critical when extruding XLPE or PVC?
Without it, barrel heat conducts backward and pellets melt prematurely, sticking to screw flights (“bridging”), causing feed starvation and surging. In XLPE it also triggers premature cross-linking at the entry. A water-cooled feed throat creates a sharp thermal boundary so pellets stay solid until the compression zone — guaranteeing stable volumetric feeding.
What maintenance routines extend extruder barrel and screw life?
(1) Purge with high-viscosity purging compound before shutdown to prevent carbonization. (2) Keep halogenated resins dry and use bimetallic barrels against HCL corrosion. (3) Periodically check gearbox–barrel–screw alignment to avoid one-sided flight wear. (4) Calibrate thermocouples regularly so displayed and actual melt temperature always match.
How is required traction speed calculated from extruder output and wire dimensions?
Line speed (m/min) = [Output (kg/h) × 1000] ÷ [60 × insulation cross-section area (mm²) × material density (g/cm³)]. UET’s PLC embeds this formula: capstan speed auto-adjusts in real time to any screw RPM fluctuation, holding wire diameter consistent across the entire run.