What does it take to execute an effective and efficient cable extrusion process?

We often hear about terrible fire incidents in commercial and industrial structures that result in the loss of human life and significant damage to surrounding property, tools, and machinery. The use of out-of-specification wires and cables is often the cause of such fire times. Therefore both the users and producers of wires and cables should have strict requirements for the quality of wires and cables.

The foundation for high-quality wire and cable is laid at the start of production. The overall quality and performance of cables, especially those used in industrial environments, depends mainly on how they are manufactured and the tools and equipment used to perform the manufacturing process. Insulation is considered to be at the heart of the quality of all types of cables, and excellent insulation quality is ensured by the use of suitable extruders, cable extruders, and appropriate extrusion technology. The following professional extruder manufacturer, Tai Zheng, will share with you the wire and cable extrusion process.

Extrusion process

Extrusion is the process used by manufacturers worldwide to create various objects with a fixed cross-sectional profile. In this process, the material is pushed into a die with the desired cross-section. The process can be performed in either a hot or cold manner. In addition, the molten material (said to be plastic) is correctly applied to the entire circumference of the wire so that it adheres to the shape and structure of the wire or cable. Extrusion is one of the most common methods for effective and efficient wire insulation and manufacturing the outer sheath of a cable.

Look at the drawing

Drawing is also considered a similar process. It strategically uses the material's tensile strength to perform the desired pulling action through the die. However, in drawing, the possibilities of the number of variations in a single step are strictly limited. This is why a drawing application is limited to simpler shapes, which usually require different stages to minimize the dimensions. Drawing is considered to be the primary method for producing wire. This method is also applicable to metal bars and pipes. The process (drawing) is usually carried out at room temperature.

Thermoplastics and thermosets: the main compounds in demand

In wire and cable extrusion, the raw material is transformed into a continuous profile designed to provide the necessary protection for wires and cables against various types of damage caused by different external factors and physical wear. Many processes are available to perform the same operation, but the main determining factor is the market demand for a specific compound. Thermoplastics and thermosets are the most common materials processed, where internal machine (barrel) friction and external thermal resistors are used to obtain complete or semi-finished products. The raw material is given the desired shape by pressing it into a mold.

Tooling design and tooling selection

Tool design and selection play a critical role in the overall quality of the insulation or sheathing. These tools need to be designed in such a way that they simplify the entire process without stagnation the material to be processed. There may be many approaches to this, but Supermac Industries India Limited, a leading manufacturer and supplier of extrusion and cable winders, has chosen the consistent and correct angle approach to achieve the right results the first time.

Advantages of using the right extrusion equipment

• Lower production costs

• Better process control accomplished by the exemplary system

• Repeat orders

• Correct tool selection leads to the superior quality of the final product

• Controlled material consumption

• Higher line speeds - higher productivity

• Top surface becomes smooth

• Better eccentricity and ellipticity

• No approximations, dimensions by calculation

Incorrect tooling can lead to defects in insulation or sheathing.

Selecting the right extruder

A pretty reasonable approach is to seek statements from different manufacturers and suppliers that synchronize output with the required extruder dimensions. Some of the most important considerations when selecting an extruder include the following：

• Horsepower requirements

• Extruder size

• Length-to-diameter ratio and screw design.

The selection of the following is equally important.

• Reduction gearboxes

• Thrust gearboxes

• right drive and PLC.

• Types of screws（The screw is considered the heart of the extruder and is designed to give a high yield of completely molten polymer.）

Taizheng is a professional extruder equipment manufacturer in China with rich experience designing and manufacturing extrusion machines. If you need to purchase a quality and reliable extruder, you are welcome to contact Taizheng.