Cable Insulation Crosshead
Foam Skin Cable Insulation Lines | Savsan Machinery
Achieving low signal loss, stable capacitance values, and homogeneous dielectric performance in telecommunications, data transmission, and high-frequency specialty cable manufacturing directly depends on the perfection of the insulation process. Savsan Foam Skin Cable Insulation Lines represent an advanced production solution engineered for high-speed thin-wall insulation, offering physical and chemical foaming technologies powered by maximum automation precision.
Thanks to its modern automation infrastructure, dynamic trough control, and flexible line configuration, it delivers maximum efficiency, reduced raw material waste, and superior product quality for your facility.
Dynamic Foaming Control and Smart Automatic Diameter Stabilization
Maintaining a consistent expansion ratio and cable outer diameter throughout the production process is the most critical technical requirement in Foam Skin extrusion:
Motorized Dynamic Hot Water Trough: Located at the initial stage of the line, the hot water trough features an integrated motorized mechanism that allows it to extend or retract dynamically. This movable structure enables micron-level precision over the cable's residence time in hot water, thereby accurately controlling the effective foaming duration.
Smart Diameter Control with Integrated Laser Sensing: Real-time feedback from downstream laser gauges is processed within milliseconds by Savsan's proprietary line control software. The system automatically adjusts physical gas injection and expansion, guaranteeing that the outer cable diameter remains stable down to a fraction of a millimeter.
Up to 1800 m/min Line Speed & Integrated Production Architecture
Savsan Foam Skin Lines are equipped with flexible hardware components engineered to seamlessly match demanding high-speed manufacturing scenarios:
1800 m/min Line Speed (In-Line Wire Drawing Integrated): With the optional integration of an in-line continuous wire drawing unit, production speeds reach up to 1800 m/min.
1250 m/min Line Speed (With Flyer Pay-Off): Configurations utilizing a high-speed flyer pay-off (without in-line drawing) deliver scrap-free operation at speeds up to 1250 m/min, depending on copper feedstock quality.
Fully Equipped Turnkey Infrastructure: The line features two high-performance extruders (dedicated for Skin and Core layers), a multi-pass capstan (MT type), integrated quality control devices (spark tester, capacitance meter, etc.), and a dual take-up unit with automatic changeover to ensure continuous production.
Broad Conductor Range & Material Flexibility
Technical capabilities designed to adapt effortlessly to diverse cable standards and material formulations:
0.40 mm – 2.40 mm Copper Conductor Range: Accommodates a wide range of copper wire sizes, from fine data communication lines to specialized conductor cables.
Insulation Diameters up to 6.00 mm: Delivers smooth and uniform insulation across various wall thicknesses.
Physical & Chemical Foaming: Supports both high-precision gas-injection physical foaming and chemical foaming processes according to customer requirements and technical specifications.
Broad Polymer Compatibility: Standard configurations process Foam Skin, Solid PE, and PVC with high thermal efficiency, with tailor-made mechanical revisions available for specialized raw materials.
Why Choose Savsan Foam Skin Insulation Lines?
Featuring minimal capacitance fluctuation, ultra-high-speed continuous operation, precision laser diameter monitoring, and heavy-duty structural integrity, Savsan Foam Skin Lines elevate your manufacturing plant's competitive strength in global markets.
Contact our expert engineering team today to discuss custom layout design, capacity calculations, and receive a competitive quotation tailored to your plant.
High Speed Insulation Line General View
Fully Automatic High-Speed Cable Insulation Lines | Savsan Machinery
Ensuring high-speed, flawless insulation across a broad product spectrum—ranging from building wires to automotive cables, signal lines, and data communications—is the fundamental factor determining the productivity of modern cable manufacturing facilities. Savsan Fully Automatic High-Speed Cable Insulation Lines guarantee scrap-free, high-concentricity insulation of both solid and stranded copper conductors ranging from 0.40 mm to 6.00 mm at line speeds up to 1250 meters per minute.
Engineered with advanced automation infrastructure, flexible extrusion options, and exceptional melt delivery stability, our line minimizes raw material waste while maximizing your plant's Overall Equipment Effectiveness (OEE).
Flexible Layering Technology & High-Speed Extrusion
Savsan High-Speed Insulation Lines feature a versatile architecture designed to adapt effortlessly to evolving market demands and global industry standards:
Broad Conductor & Diameter Compatibility: High-speed capability and continuous stability across solid and stranded conductor groups from 0.40 mm to 6.00 mm.
Production Speeds up to 1250 m/min: High line speeds up to 1250 meters per minute, optimized according to cable type, insulation material, and conductor cross-section.
Multi-Layer & Color Striping Versatility: Seamlessly perform single-layer, dual-layer (skin-core), or skin-color striped extrusion applications within a single unified line infrastructure.
CH 4/6 Self-Centering Crosshead & Bypass Technology
Wall thickness uniformity (concentricity) and rapid color/formula changeovers directly impact operational efficiency in cable extrusion:
Self-Centering CH 4/6 Extrusion Crosshead: Eliminates the need for manual adjustment, ensuring automatic and precise wire centering. This reduces downtime and defect risks to absolute zero.
Optional Bypass Unit: Integrated directly onto the crosshead, the bypass system allows melt purging during resin or color changes without stopping the production line.
Broad Polymer Compatibility & Industry Applications
Delivering linear throughput efficiency, Savsan’s extruder engineering provides stable melt delivery across all thermoplastic and cross-linked polymers:
Processable Insulation Materials: PVC, PE, XLPE, and halogen-free flame retardant (HFFR / LSOH) polymers.
Comprehensive Product Portfolio:
Automotive primary wires (FLRY series, etc.)
Low voltage & building wires (NYA, NYAF, etc.)
CAT 5 & CAT 6 data/telecom cables (select types)
Control and signal cables
Low Scrap Rate & High Operational Efficiency
Thanks to Savsan Machinery's custom barrel and screw engineering, head pressure and melt temperature remain in ideal balance regardless of line speed fluctuations. This stability dramatically lowers scrap rates and raw material loss, particularly during startup sequences.
Why Choose Savsan Fully Automatic Insulation Lines?
With a robust mechanical chassis, high-speed extrusion stability, international automation standards integration, and a commitment to continuous technical support, Savsan Machinery is the guarantee of quality and competitiveness in your cable production lines.
Contact our expert engineering team today to explore custom line configurations, technical specifications, and competitive quotations tailored to your plant.
Insulation Line General View
Medium Cross-Section Cable Insulation Lines | Savsan Machinery
Achieving high operational efficiency and precision insulation across a broad product spectrum—ranging from low-voltage power cables to solar PV cables, building wires, and flexible control lines—is the primary objective of modern cable manufacturing facilities. Savsan Medium Cross-Section Cable Insulation Lines deliver scrap-free, high-concentricity insulation with uniform wall thickness for solid and stranded conductors up to 20 mm outer diameter at line speeds reaching 800 meters per minute.
Driven by advanced extruder engineering, modular line architecture, and versatile raw material processing capabilities, our insulation line minimizes raw material waste while maximizing your plant's Overall Equipment Effectiveness (OEE).
Up to 800 m/min Line Speed & Flexible Layering Architecture
Savsan Medium Cross-Section Insulation Lines feature a highly adaptable system built to accommodate diverse technical specifications and production requirements:
20 mm Diameter Capacity: Superior hauling stability across conductor and cable groups with outer diameters up to 20 mm.
Production Speeds up to 800 m/min: High-speed, continuous operation reaching up to 800 m/min, optimized according to cable cross-section and insulation resin.
Multi-Layer & Striping Extrusion Versatility: Seamlessly perform single-layer, dual-layer (skin-core), and skin-color striped insulation applications within a single integrated line configuration.
Adjustable Extrusion Crossheads & Modular Line Integration
Precision mechanical solutions are engineered into the line to ensure high concentricity and a smooth surface finish throughout the extrusion process:
Precision Adjustable Crossheads: Scalable, adjustable extrusion heads matched to cable diameter and process criteria deliver perfect melt distribution and uniform wall thickness.
Seamless Turnkey Integration: Modular integration of various capacity pay-offs, take-ups, capstans, and horizontal/vertical accumulators tailored specifically to your production scenario.
Minimized Scrap Rates: Extruders engineered with a linear throughput performance curve maintain ideal head pressure and melt temperature, dramatically reducing raw material loss during startup sequences and stops.
Broad Polymer Compatibility & Sectoral Applications
Offered with versatile screw and barrel options, the line efficiently processes the industry's most common polymer compounds:
Processable Insulation Materials: PVC, PE, XLPE, and halogen-free flame retardant, low-smoke polymers (HFFR / LSOH).
Diverse Cable Portfolio:
Solar PV (Photovoltaic) cables
Low-voltage power cables
Building wiring (NYA, NYM series, etc.)
Flexible control and signal cables
Why Choose Savsan Medium Cross-Section Insulation Lines?
Featuring high production speeds, broad material adaptability, stable extrusion output, and heavy-duty mechanical construction, Savsan Medium Cross-Section Insulation Lines elevate your cable manufacturing facility's competitive edge in international markets.
Contact our expert engineering team today to discuss custom layout designs, technical specifications, and receive a competitive quotation tailored to your plant.
Insulated Cable Sample
Heavy-Duty Cable Insulation Lines (20 mm – 120 mm) | Savsan Machinery
In the manufacturing of heavy-duty power cables, energy transmission lines, and large cross-section industrial cables, delivering high throughput, excellent concentricity, and continuous process stability is essential for operational efficiency. Savsan Heavy-Duty Cable Insulation Lines enable scrap-free insulation and sheathing for conductors and cable bundles ranging from 20 mm to 120 mm in diameter, achieving uniform wall thickness at production speeds up to 300 meters per minute.
Built on a project-specific flexible 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).
High Capacity & Flexible Layering Architecture
Savsan Heavy-Duty Insulation Lines are engineered to withstand the demanding torque and haul-off requirements of large-diameter cable manufacturing:
20 mm – 120 mm Diameter Range: Accommodates a wide diameter spectrum, from low- and medium-voltage power cables to heavy industrial jacketing/sheathing processes.
Production Speeds up to 300 m/min: High-speed extrusion and pulling performance reaching up to 300 m/min, optimized according to cable cross-section, wall thickness, and polymer formulation.
Multi-Layer Extrusion Technology: Precision execution of single-layer, dual-layer, and color-striped extrusion applications within a single unified production line.
Adjustable Extrusion Crossheads & Custom Line Integration
To eliminate wall thickness variations in large-diameter cables and optimize production setup times, the system incorporates heavy-duty mechanical solutions:
Precision Adjustable Crossheads: Custom-selected adjustable extrusion heads ensure uniform melt distribution, delivering flawless wall concentricity and smooth surface finish even under high head pressures.
Modular & Tailor-Made Line Configuration: Fully customizable layouts equipped with heavy-duty Gantry/Portal Pay-Offs and Take-Ups, high-torque Caterpillar haul-offs, capstans, and horizontal/vertical accumulators tailored to your plant footprint.
Reduced Scrap Rates: Featuring a linear output curve, Savsan's extruder technology maintains optimal head pressure to minimize raw material waste during startup sequences and line stops.
Broad Polymer Compatibility & Heavy-Duty Applications
Capable of processing demanding polymer compounds with high thermal efficiency and melt homogeneity:
Processable Insulation & Sheathing Materials: PVC, PE, XLPE, and halogen-free flame retardant (HFFR / LSOH) low-smoke compounds.
Key Application Areas:
Low- and medium-voltage heavy power cables
Power distribution and infrastructure utility cables
Armored industrial and heavy flexible control cables
Outer jacketing and sheathing extrusion processes
Why Choose Savsan Heavy-Duty Insulation Lines?
Featuring robust mechanical structures built for continuous heavy loading, low maintenance requirements, exceptional energy efficiency, and bespoke engineering flexibility, Savsan Machinery is your trusted partner in heavy-duty cable manufacturing.
Contact our expert engineering team today for custom layout proposals, capacity analysis, and competitive quotations tailored to your production facility.
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