Industrial automation and IoT solutions for cable manufacturing

With over 40 years of experience in cable production automation, Elav offers advanced digital and software solutions for intelligent production management, process optimization, and data traceability in line with Industry 4.0 standards.

Elav’s IoT solutions are modular, scalable, and easily integrated with the customer’s ERP systems, seamlessly interfacing with both new and existing production lines.

Live Control – MES software for cable manufacturing

Live Control is Elav’s MES system developed for real-time production monitoring and management. Designed specifically for the wire and cable industry, it collects and visualizes data directly from the field, providing a comprehensive and up-to-date overview of the line status.

The software allows detailed analysis and historical tracking of consumption, machine parameters, cycle times, quality, and overall process performance. With these features, full product traceability can be achieved, reel by reel, improving operational control and compliance. Implementing Live Control also optimizes production efficiency and significantly reduces energy and maintenance costs.

Key features:
- Machine parameters (temperatures, pressures, diameters, speeds, loads)
- Data history and storage
- Production and detailed reports (e.g., by production order or reel)

Optional functions:
- Material monitoring (quantities, batch, actual vs expected consumption)
- OEE (Overall Equipment Effectiveness)
- Recipe and cycle management
- Alarms and fault management
- Quality control (interface with spark testers, lump & neck detectors, diameter gauges, etc.)
- Maintenance management (scheduled and on-demand)
- ERP interface (SAP®, Microsoft Dynamics NAV, etc.)
- Defect tracking

MarkOne – Universal marking system

MarkOne is Elav’s marking solution for cables, compatible with major industrial inkjet printing systems. The system is:

- Universal: can be integrated with leading industrial printer manufacturers
- Interfaced: easily connected to all ERP/MES management software
- Ideal for centralized management: allows automatic parameter setup, avoiding errors and reducing setup times

With MarkOne, marking configuration can be fully automated according to the cable type in production, ensuring precision, brand consistency, and complete traceability.

Automation systems for cable production lines

Elav’s offering also includes customized automation solutions for:
- Rod breakdown, bunching, and stranding lines
- Single extrusion, co-extrusion, and tandem extrusion lines
- Curing (vulcanization) lines
- Dosing and feeding systems
- Winding, pay-off, and rewinding systems
- Synoptic control via HMI and operator panels

All Elav control systems use Siemens PLC technologies and intuitive HMI interfaces, customizable according to line type and customer standards.

CableWizard: the new control system developed by Elav to manage cable extrusion lines intuitively, simply by defining cable properties.

With Live Control, MarkOne, and CableWizard, your line becomes an intelligent, connected, and future-ready platform. Contact Elav for personalized consulting.