Home / Product / Wire Insulation Extrusion Machine / Foaming Wire Insulation Extrusion Line / FOAM PE/PP/PU Chemical Foaming Core Wire Insulation Extrusion Line

Product

Foaming Wire Insulation Extrusion Line

FOAM PE/PP/PU Chemical Foaming Core Wire Insulation Extrusion Line

FOAM PE/PP/PU Chemical Foaming Core Wire Insulation Extrusion Line is a non-standardized equipment with customization. The main machine model is generally 35-60mm. It is suitable for core wire insulation extrusion of chemical foaming materials for signal cable. Foaming extrusion can reduce the dielectric constant of the insulating layer, enlarge the skin effect of electron transmission, reduce signal attenuation, and increase the signal transmission distance. During the foaming extrusion process, the pressure and temperature inside each zone of the extruder barrel determine the material's finished foaming density. Temperature and pressure are proportional to each other and it is important to control extrusion pressure and temperature. For parts where material flows, pressure remains consistent and the temperature is controlled within ±1°C to maintain stable pressure and the material's foaming degree. Due to the poor strength of the foamed insulation layer, solid skin is covered on the outer layer of the foamed layer in order to enhance the strength of the core wire, thus chemical foaming extrusion is mostly double-layer extrusion. An desirable chemical foam core wire insulation extruder has the following characteristics: smooth screw barrel and non-sticky to materials, materials mixed well and foams evenly by screw, accurate temperature control, good fluidity with no obstruction of machine head chanel, high concentricity of the machine head, stable wire diameter, small tolerance,  stable capacitance, stable pay-off, and take-up tension, etc. Our company can support personalized customization according to user needs. In terms of hardware, we can provide a variety of models and core accessories brands for users to choose from. In terms of electrical control software, we can also provide economical and practical or the most advanced electrical control methods. Due to different overall configurations, the price of this machine also varies greatly. Therefore, the main factor that determines the price of this machine is the user's product configuration level positioning. In addition, because this product is a non-standardized customized equipment with only small lot production, it takes longer period for design, manufacturing, installation, and debugging cycle is long. Users must reserve sufficient procurement cycles to achieve perfect product delivery.

Inquiry +
Product Details

COMPONENTS

Pay-off stand
Straightening stand
Preheater
Main extruder
Injection machine
Extruder head
BY-PASS material discharge valve
Feeding hopper dryer
Constant temperature movable flume
Cooling water tank
Water electrostatic capacitors
Air blowing nozzle
Capstan
Wire accumulation stand
Meter counter
Laser diameter gauge
High-frequency spark tester
Take-up
Electricity Control Box
The following are custom options
Printer
Vacuum device
Blow dryer
Lump detector
Eccentricity gauge
Electronic billboard
Other peripheral auxiliary equipment can be customized and added.

TECHNICAL SPECIFICATIONS

Main Technical Parameters 35+25type 40+30type 45+35type 50+35type 60+40type
Suitable wire type Suitable for high-frequency cable, data cable, signal cable, electronic cable and other wires of the copper wire conductor chemical foam insulation extrusion.
Conductor range for US standard AWG36-30 AWG34-28 AWG32-26 AWG30-22 AWG28-18
Conductor diameter range Ø0.13-0.25mm Ø0.16-0.32 Ø0.20-0.40mm Ø0.25-0.65mm Ø0.32-1.02mm
Conductor area range 0.01-0.05m㎡ 0.02-0.08m㎡ 0.03-0.13m㎡ 0.05-0.32m㎡ 0.08-0.81m㎡
Extrusion outer diameter Ø0.5-0.8mm Ø0.6-1.0mm Ø0.8-1.2mm Ø1.0-1.6mm Ø1.3-2.5mm
Wire speed range 20-200m/min 30-300m/min 40-400m/min 50-500m/min 60-600m/min
Machine structure Take the extruder head as the central axis, all parts from pay-off to take-up is linearly distributed. The standard extrusion line has a center height of 1 meter and a total length of 24-28 meters
Pay-off type Standard shaftless active pay-off stand, electric lifting, pneumatic tightening, other types such as flyer pay-off, shaft type and other power pay-off stand can also be customized.
Pay-off specifications Ø200/300 Ø300/Ø400/Ø500 Ø400/Ø500/Ø630
Pay-off power 3.7KW 5.5KW 7.5KW
Pay-off tension type Move or adding/removing counterweight blocks to adjust tension, and it can also be customized to adjust the tension with a servo motor.
Straightening rack 5-wheel conductor straightening frame, conductor straightening wheel is OD Ø60, single groove, with tool box.
Type of preheater Closed oven preheater with hot air circulation, conductor type copper wire preheater or straght through preheater can be customized.
Power of preheater 8KVA
Speed of extruder MAX90RPM
Extruder output 30kg/h 40kg/h 50kg/h 60kg/h 90kg/h
Extruder Power 7.5KW 11KW 15KW 22KW
Screw parameters L/D ratio is 28:1, compression ratio is 3.0. It consists of 38CrMoAlA screw material and can be customized.
Heating type Cast aluminium heating rings for the body, copper heating rings for the neck, quartz heating tubes for the extruder head clamps/heads/die.
Number of temperature control  Body 4+clamp 1+neck 1+head 1+die 1
Power of machine heating 6KW 8KW 9KW 10KW 14KW
Barrel cooling 4-section centrifugal fan
Feeding hopper dryer 12KG 25KG 50KG
Injection machine power Horizontal strip-injection machine with 3-stage temperature control for the body and 1-stage temperature control for the neck, vertical strip-injection machine can also be customized.
Injection machine ouput 6kg/h 10kg/h 15kg/h 15kg/h 25kg/h
Injection machine power 2.2KW 3.7KW 5.5KW
Honeycomb plate The machine is made of 316 stainless steel without electroplating. It has an internally guided flow structure, with flow holes interconnected by chamfers with no dead corners. The honeycomb plate and flange are sealed with a tapered sealant to prevent leakage.
Head type ​U7-type auto-centering head, outer runner uniform pressure movement, can be customized with different structures such as single layer/double layer/single injection strip/double injection strips etc., and  (auto centering + micro adjustable) extruder head can also be customized.
Head brand The machine head is made in China and can be customized to other brands such as EUROTEK, UNITEK, EUROCAB, and MICRODIA
Head clamp There are two halves of a machine head clamp, with two up-and-down sets of screws rod clamp synchronizely. A one-way wrench can be included, and other types of machine head clamps can be customized.
Pressure test Standard is without pressure detection function, pressure sensors or explosion-proof safety valves can be added to the head flange.
BY-PASS material discharge valve BY-PASS Material Discharge Valve 
Head levelling Adopting a head flange double locating pin structure, the height level of the head remains unchanged for a long time.
Movable flume Constant temperature movable flume, self-circulating temperature tank. It is equipped with two 9KW heating pipes, and the entire tank is made of SUS304 material. The standard length of the small tank is 1250mm, and customization options are available. 
Cooling tank 10-meter single-layer U-shaped tank, circulating water cooling system, no water chiller. The entire tank is made of SUS304 material. Double-layer U-shaped or W-shaped tanks are available for customization.
High-pressure air-blowing nozzle Flipped-type blowing nozzle, POM material, double blowing structure, set in the movable water tank, cooling water tank, capstan. Other types of blowing nozzle type can be customized.
Capstan type Lightweight titanium alloy and wear-resistant stainless steel dual-wheel capstan
Capstan wheel diameter Ø375 high-strength titanium alloy double wheel design. 
Capstan power 3.7KW servo motor.  
Wire accumulation tension stand Inclined wire accumulation tension stand, total length of 12 meters, steel plate track, lightweight running car, 10 grooves + 9 grooves for wire accumulation wheel, total wire storage capacity is 180 meters. Servo motor tension, other types are available. 
Wire accumulation wheel diameter Ø120, can be customized  Ø150, can be customized  Ø180, can be customized 
Meter counter Guide wheel type meter counter with a meter wheel circumference of 400mm. It uses an encoder to detect and allows for fine adjustment of the meter correction coefficient. Other types of meter-counting devices are available. 
Take-up type Double-head shaft type take-up, automatic reel changing type or other non-shaft wire take-up machines can be customized.
Take-up reel spcification Ø200/300/Ø400 Ø300/Ø400/Ø500 Ø400/Ø500/Ø630
Take-up power 2.2KW 3.7KW
Take-up wire arrangement 0.4KW servo motor for wire arrange 
Water electrostatic capacitors BETA water static capacitor, other brands, such as BETA/SIKORA/ZUMBACH/PROTON/TAKIKAWA, can be customized. 
Laser diameter gauge Made-in-China wire diameter gauge, single-axis type, measurement accuracy is 0.001, other brands, such as SIKORA/ZUMBACH/PROTON/TAKIKAWA, etc are customizable.
High-frequency spark tester Made-in-China bead-type high-frequency spark tester, voltage is 0-15KV, other brands, such as CLINTON/SIKORA/PROTON can be customized.
Electricity control box Environmentally friendly flame-retardant paint-coated VICTOR electric cabinet, WEINVIEW 10” HMI, SIEMENS PLC, SCHEIDER switches, RKC temperature controller. Motor and frequency converter brands are customizable.
Total power 54KW 65KW 70KW 75KW 90KW


OPTIONAL CUSTOMIZATION ITEMS

Capstan wire drop device Core wire insulation extrusion capstan without wire drop device can be customized to add one.  
Printer Ink printer or other printing type can be customized.
Vacuum extractor A vacuum device can be added at the head of the machine upon customization. 
Blow dryer High efficiency blow dryer can be customized when the machine is in high-speed extrusion.
Lump detector Customizable option to add lump detection features to the measuring instrument on Chinese brands diameter gauge, or customize other brands like SIKORA/ZUMBACH/PROTON/TAKIKAWA.
Eccentricity gauge Eccentricity gauge, such as BETA/SIKORA/ZUMBACH/PROTON/TAKIKAWA, can be customized.
Chiller Chiller or tank with insulated layer can be customized.
Hanging electronic board LED double-sided electronic screens or other types are supported.
Intelligent formula management system Intelligent formulation management systems can be customized, and data such as take-up tension, storage line tension, preheating temperature, host temperature control, extrusion diameter, take-up row distance, air pressure values will be fed into the PLC. It uses Profinet bus communication mode, support for MES data acquisition and import, one-key call-out production process, one-key start-up, and enables digital intelligent products.
Peripheral auxiliary Equipment Other peripheral accessories or special customizations for the entire machine can be customized.
Electrical wiring 2.5-meter overhead cable trough stand, air pipes, signal wires, and power cable arranged with isolations, wire inlet from the top of electrical control box, customizable alternative methods.
Safety regulations standard Manufactured in accordance with China's CCC safety standards, and customizable to meet CE/CSA/UL safety standards.
Power supply standards 3-phase 380V/50Hz power supply, with customizable voltage and frequency for different countries and regions.




PRODUCT FEATURES

High production yield: Screw-optimized design, wear-resistant, non-stick, chrome without dropping, glue-free hiding, fast color change, high line speed, high production yield.

Leak-proof design: The unique sealing and positioning structures ensure that the flange does not leak material, and the height level of extrusion head remains stable even for long-term use.

High Quality: Our insulated wires have a concentricity of 93%-97%, an outer diameter variation of ±0.005, and a capacitance variation of ±1pf/m

Precise Temperature Control: within ±1℃.

Intelligent: Our intelligent management system can be customized, allowing for easy access to SOP formulas, one-click startup preparations, and intelligent operation.

Easy maintenance: Customers outside of China can customize the use of the Profinet bus control system, which ensures fast and low-interference signal transmission. As long as there is a communication network in any country or region, remote fault detection, troubleshooting, and maintenance services can be quickly implemented.

  • 0

    Establishment time

  • 0

    Building area (m²)

  • 0

    Number of employees

  • 0+

    Intellectual property

A Mature Factory You Can Count On

Gemwell Electrical Machinery Co., Ltd.
Founded in 2005, GEMWELL is a professional wire and cable equipment solution provider in design, manufacture and sales for the United States, Canada, Mexico, Germany, Italy, India, Thailand, Russia and etc. more than 40 countries in the world.

The success of customer is our goal to get success!

● Focus on technological innovation, quality stability, precision manufacturing and considerate service.
● Insist on making all in detail well, repay every customer with high quality.
● Take customer's success as the embodiment of our enterprise value.

The enterprise spirit of dedication, dedication, enterprise and exploration encourages us to innovate and transform the technology of wire and cable into advanced productive forces, in order to build GEMWELL into a new name card of China facing to the world.
Guaranteed Quality
Certifications
Read More +
NEWS & EVENT
Latest Updates