Cable Sheathing Line
Sample Small Diameter Sheathing Cable
Small-Diameter Cable Sheathing Lines | Savsan Machinery
In the outer jacketing and sheathing processes of power, control, telecommunications, and building wires, achieving high surface quality, precise wall thickness, and continuous production speeds directly defines the physical durability and compliance of the final cable. Savsan Small-Diameter Cable Sheathing Lines are engineered as a modern production solution designed to deliver scrap-free, highly efficient, and consistent jacket extrusion for cable bundles up to 20 mm outer diameter at line speeds reaching 600 meters per minute.
Centralized PLC Automation & Synchronized Speed Control
Savsan Small-Diameter Sheathing Lines feature an advanced automation architecture that allows precise centralized management of all line parameters:
Fully Integrated Line Architecture: The turnkey line incorporates a high-performance pay-off, main extruder, cooling troughs, high-pressure air wiper/dryer, capstan haul-off, and take-up unit.
Single-Point Touchscreen Operation: All main machinery components are centrally synchronized via a user-friendly industrial PLC software interface and intuitive touchscreen panel.
Superior Wall Thickness & Low Scrap Rates: The intelligent control system dynamically synchronizes line speed with extruder screw RPM in real time. This guarantees millimeter-precise wall thickness and surface smoothness throughout the line while radically reducing raw material waste during startup sequences and line stops.
Multi-Layer Flexibility & Broad Polymer Compatibility
Versatile Sheathing Applications: Standard infrastructure supports single-layer, dual-layer (co-extrusion), and color-striped jacket extrusion processes.
Up to 600 m/min Line Speed: High haul-off and jacketing performance reaching up to 600 meters per minute, optimized according to cable type, cross-section, and sheath wall thickness.
Comprehensive Material Range: High-efficiency processing of PE, PVC, XLPE, and low-smoke, flame-retardant polymers (HFFR / LSOH / LSZH). Tailor-made screw and barrel geometries are custom engineered by Savsan for specialized compounds and sensitive polymers.
Modular Structure & Scalable Optional Equipment
Designed to adapt seamlessly as your plant footprint and product portfolio expand, the line's flexible modular architecture supports a wide range of optional hardware:
Co-Extrusion & Ancillary Units: Additional co-extruders for skin/stripe applications, as well as auxiliary pay-off and take-up units.
Infrastructure & Process Enhancements: Space-saving double-deck cooling troughs, hot water circulation systems, horizontal or vertical accumulators for continuous reel changes, and talc/powdering units to prevent cable surface adhesion.
Why Choose Savsan Small-Diameter Sheathing Lines?
Delivering flawless outer surface finish even at elevated line speeds, a scalable modular chassis, low operational costs, and dependable technical support, Savsan Machinery enhances your plant's competitive edge in cable jacket extrusion.
Contact our expert engineering team today to explore custom line configurations, technical specifications, and receive a competitive quotation tailored to your facility.
Cable Sheathing Line General View
Cable Sheathing Lines (up to 120 mm) | Savsan Machinery
In the outer sheathing and jacketing processes of power transmission lines, low- and medium-voltage power cables, solar PV cables, and flexible control lines, achieving high abrasion resistance, precise wall thickness, and flawless surface finish directly defines the service life and standard compliance of the final cable. Savsan Cable Sheathing Lines are engineered to heavy-duty industrial standards to deliver scrap-free, highly efficient, and consistent jacket extrusion across a wide spectrum of cable bundles up to 120 mm outer diameter at production speeds reaching 300 meters per minute.
Built on a flexible, project-specific engineering architecture, heavy-duty line components, and extruder technology delivering consistent melt output, our solution reduces operational costs while maximizing your plant's Overall Equipment Effectiveness (OEE).
Precision Centering & Multi-Layer Extrusion Technology
Savsan Cable Sheathing Lines are equipped with advanced mechanical systems designed to eliminate wall thickness variations and surface defects in large-diameter cables:
120 mm Diameter Capacity & 300 m/min Line Speed: Delivers high haul-off and jacketing performance up to 300 meters per minute across a broad operational scale, from heavy power cables to flexible jacketing lines.
Adjustable Extrusion Crossheads: Custom-selected adjustable extrusion crossheads ensure uniform polymer melt distribution around the core—even under high barrel pressures—delivering superior wall concentricity and repeatable quality.
Flexible Layering Architecture: Supports single-layer, dual-layer (co-extrusion), and color-striped jacket extrusion applications within a single unified line infrastructure.
Modular Configuration & Low Operational Costs
Heavy-Duty Line Components: Integrated with high-torque caterpillar haul-offs, large-flange Gantry/Portal pay-offs and take-ups, and high-capacity cooling troughs tailored to your specific production scenarios.
Linear Extruder Output Efficiency: By maintaining optimal head pressure and melt temperature, Savsan extruder technology dramatically lowers raw material waste and scrap rates during line startups and stops.
Project-Based Custom Engineering: Bespoke line modifications and technical integration support tailored specifically to your facility's footprint and operational goals.
Broad Polymer Compatibility & Industry Applications
Featuring specialized screw and barrel metallurgy paired with precision temperature control, the system adapts effortlessly to diverse raw material formulations:
Compatible Sheathing Compounds: Processing of PE, PVC, XLPE, and low-smoke, flame-retardant polymers (HFFR / LSOH / LSZH).
Diverse Cable Portfolio:
Solar PV (Photovoltaic) outer jacketed cables
Low- and medium-voltage heavy power cables
Building wiring and utility infrastructure cables
Flexible control and industrial cables
Why Choose Savsan Cable Sheathing Lines?
Combining advanced automation infrastructure, structural integrity built for demanding industrial environments, minimal scrap rates, and expert post-sales technical consulting, Savsan Machinery enhances your plant's global competitive edge in cable jacket extrusion.
Contact our expert engineering team today to explore bespoke project designs, technical specifications, and receive a competitive quotation tailored to your plant.
Sample Tandem Filling and Sheathing Line Layout
Tandem Filling and Outer Sheathing Extrusion Lines | Savsan Machinery
In the manufacturing of energy power cables and multi-core cables, executing the inner filling layer and outer sheathing processes consecutively (in tandem) on a single unified line dramatically reduces raw material costs while delivering flawless surface finish and superior aesthetic appeal. Savsan Tandem Filling and Sheathing Lines maximize cost-to-performance efficiency by applying a high-quality, uniform, and precisely colored outer jacket over a cost-effective inner filling core.
Operating at line speeds up to 100 meters per minute for cable bundles up to 120 mm outer diameter, this system combines a heavy-duty frame structure, standard integrated talc powdering unit, and tandem extrusion technology to offer a versatile solution that elevates your plant's overall productivity.
Dual-Layer Production & Cost Efficiency via Tandem Technology
Optimizing consumption of jacket and filler raw materials—which account for a significant portion of overall cable production costs—directly strengthens your facility's competitive advantage:
Dual-Layer Cost Optimization: Economic filler compounds are used to fill internal voids, while the outer sheath is extruded using high-grade polymers resistant to physical and chemical exposure with superior surface quality.
Two Processes in a Single Pass: By eliminating the need to process cables through two separate production lines, the tandem architecture delivers substantial savings in labor, energy, and overall cycle times.
Standard Integrated Talc Powdering Unit: A talc powdering unit is supplied as standard on the line to prevent adhesion between the inner filler and outer sheath, ensuring effortless core separation.
120 mm Diameter Capacity & Modular Line Configuration
Engineered with a modular infrastructure designed to withstand high mechanical loads and torque requirements of heavy-duty cable manufacturing:
120 mm Outer Diameter Capacity: Safe and stable operation across low- and medium-voltage power cables and multi-core industrial cables up to 120 mm outer diameter.
Line Speeds up to 100 m/min: Haul-off and jacketing performance reaching up to 100 meters per minute, optimized according to the selected line configuration, wall thickness, and polymer formulation.
Infeed & Outfeed Caterpillar Integration: High-torque inlet and outlet caterpillar haul-offs ensure the cable passes through the tandem extrusion crossheads under precisely controlled, constant tension.
Flexible Hardware Options: Scalable integration with various extruder sizes, Gantry/Portal pay-offs and take-ups, and horizontal or vertical accumulators tailored to your plant requirement.
Precision Centering & Broad Polymer Compatibility
Adjustable Extrusion Crossheads: Precision-engineered adjustable crossheads selected to match specific cable diameters guarantee uniform thickness distribution for both filler and outer sheath under high barrel pressures, delivering flawless concentricity and repeatable quality.
Linear Extruder Output: Maintaining steady head pressure and melt temperature, Savsan extruder technology minimizes raw material loss and scrap rates during line startups and stops.
Comprehensive Material Range: Fully compatible with PVC, PE, XLPE, and low-smoke, flame-retardant polymers (HFFR / LSOH / LSZH).
Project-Based Custom Engineering & On-Site Integration
Savsan Machinery delivers Tandem Filling and Sheathing Lines backed by custom project-based engineering tailored to your facility's layout footprint and specific operational targets. Application consulting, field installation, and full technical integration are executed end-to-end by expert Savsan engineers.
Why Choose Savsan Tandem Filling & Sheathing Lines?
Combining significant raw material savings, smooth outer sheath aesthetics, heavy-duty mechanical endurance, and bespoke project engineering support, Savsan Machinery enhances the profitability and market position of your cable manufacturing facility.
Contact our expert engineering team today to explore custom project designs, technical specifications, and receive a competitive quotation tailored to your plant.
For Information and Requests
For detailed information, your questions and requests please contact us. Our sales team will reply you in the shortest time.
