Insulation and sheathing extrusion lines for power cables

Elav designs and manufactures modular extrusion lines for producing power cables, suitable for both insulation and sheathing processes. These solutions are ideal for applications in electrical distribution, infrastructure, industrial energy, and power transmission sectors.

Elav lines can process a wide range of thermoplastic materials, including PVC, PE, XLPE Sioplas, XLPE Monosil with liquid silane injection, HFFR, PP, PU, and TPE, ensuring dimensional stability, continuous operation, and consistent final product quality. Available configurations include single extruders, co-extrusion, and tandem systems for integrating multiple functions.

Line configuration

Each Elav insulation and sheathing line can be customized according to the specifications of the power cable to be produced and may include:

• Pay-offs: sliding arms (SSM), portals (SPT), or defilè pay off with capstan for equalizing tension or traction control
• Extruders (LCE series): diameters from 80 to 160 mm for insulation, sheathing, filling, or skin
• Dosing systems: volumetric, gravimetric, batch systems for complete compounds, also with top-precision liquid silane injection (patented Si-Jet®)
• Extrusion heads: configurable for single or co-extrusion
• Cooling troughs: straight, heated/cooled sections, single or multistep
• Capstans/Caterpillars: TCP or TCT series for controlled pulling
• Accumulators: vertical (ACV) or horizontal (ACH), for reel changes without line stopping
• Take-ups: traditional take-ups (sliding arms, cantilever, portals), double automatic ADA series, or semi-automatic ADS series

Insulation extrusion lines

Elav’s insulation lines are ideal for low-voltage applications. Available with a single extruder or in Coex 2 configurations (with striping), they deliver precise, continuous, and high-speed coverings.

Technical data:
Cable cross-section: 1 mm² – 800 mm²
Cable diameter: up to 50 mm
Processable materials: PVC, PE, XLPE Sioplas, XLPE Monosil with liquid silane, HFFR, PP, PU, TPE
Line speed: up to 1,200 m/min

Sheathing extrusion lines

Sheathing lines are designed for assembled cables, with optional modules for filling and skin layer application. Available in single, Coex 2, Coex 3, or tandem configurations, these lines are optimized for insulating and flame-retardant materials.

Technical data:
Assembled cables
Processable diameter: 30 mm – 200 mm
Processable materials: PVC, PE, XLPE Sioplas, XLPE Monosil with liquid silane, HFFR, PP, PU, TPE
Line speed: up to 500 m/min

Rely on Elav for the design of complete lines for power cable production: modularity, automation, and performance to support your manufacturing needs.