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Cable Compounding

Extrusion lines for every compound in a power or data cable: PE insulation and sheathing, crosslinkable XLPE for 10 kV and 35 kV, semiconductive screens, PVC and halogen-free flame retardant (HFFR) compounds.

  • PE
  • XLPE
  • Semiconductive
  • PVC
  • HFFR
Get a quote →Compare the routes

One cable, five compounds

Each layer of a cable is a different compound with a different process. Find your layer, then jump to its line.

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  1. 1 · Conductor screen

    Semiconductive compound: PE / EVA + carbon powder

    Semicon

  2. 2 · Insulation

    PE, silane XLPE for 10 kV, peroxide XLPE for 35 kV, plasticised PVC, HFFR

    PEXLPEPVCHFFR

  3. 3 · Insulation screen

    Semiconductive compound, silane or peroxide type to match the insulation

    Semicon

  4. 4 · Metallic screen

    Copper tape or wires, not a compound

  5. 5 · Sheath

    PE sheathing compound, plasticised PVC, HFFR / LSZH

    PEPVCHFFR

Cut-away of a multi-core power cable with a red outer sheath
Photo provided by BLS Polymers (India).

Six compounds, six routes

The formula decides the machine. Filled and heat-sensitive compounds go through a kneader or a second, single screw stage; clean polymer compounds go straight through a twin screw extruder.

Ask for a configuration →
CompoundBasic formulaProcessPelletizingOutput
PE insulation & sheathingLDPE / LLDPE / MDPE / HDPE + 2–5% pigment or carbon black + additivesKneaderConical force feederSingle screwor mixer / loss-in-weight feeding → twin screwWater ring250–1,100 kg/h
Silane XLPE · 10 kVA + B materialsA: PE + DCP + silane + anti-oxidant · B: PE + DBTL catalyst + anti-oxidantLoss-in-weightTwin screw L/D 56B: low-torque twin screw, L/D 40On requestdryer, vacuum packing150–1,100 kg/h
Peroxide XLPE · 35 kVLDPE + DCP + anti-oxidantLoss-in-weightTwin screwSingle screwtwo stages to hold melt temperatureIon-free cooling waterdryer, vacuum packing400–850 kg/h
Semiconductiveperoxide & silanePE / EVA + carbon powder + DCP + anti-oxidantKneaderConical force feederSingle screwAir-cooling die face350–600 kg/h
PVC cablePVC 60% + DOP 20% + calcined clay 10–20% + CaCO₃ 0–10% + heat stabiliser + additivesTwin screwSingle screwtandemOn request250–2,500 kg/h
HFFR / LSZHPE 10% + EVA 30% + ATH 55% + additives 5%KneaderForce feederTwin screwSingle screwor loss-in-weight → triple screw → single screwAir-cooling die face250–1,000 kg/h

Output ranges are the span of the model tables in each section below.

PE insulation and sheathing compound

Our PE compounds are based on polyethylene or its co-polymers, modified to the client's specification. Three types of process, all with water ring pelletizing.

Basic formula
  • LDPE / LLDPE / MDPE / HDPE
  • Pigment / carbon black2–5%
  • Additives

Process 1

Kneader + single screw

  1. Kneader
  2. Conical force feeding
  3. Single screw
  4. Water ring
Output
600–1,100 kg/h

Process 2

Mixer + twin screw

  1. Mixer
  2. Twin screw
  3. Water ring
Output
250–900 kg/h

Process 3

Loss-in-weight + twin screw

  1. Loss-in-weight feeding
  2. Twin screw
  3. Water ring
Output
250–900 kg/h
Kneader, conical force feeder and single screw extruder for PE insulation and sheathing compound
Kneader, conical force feeder and single screw extruder (process 1).
ModelKneader Volume (Liter)Screw Diameter (mm)Screw Speed (rpm)Motor (kW)Output (kg/h)
K75-TDD1807518075110/90600–700
K110-TDD22011022075160/110900–1100

Crosslinkable PE (XLPE) insulation

Crosslinking stops the PE molecules moving against each other under heat. An XLPE cable runs hotter, carries a higher current than its PVC equivalent, and has one of the best water resistances. Almost all XLPE cable compounds are based on LDPE.

Rated

90 °C

Maximum conductor temperature

Emergency

140 °C

Depending on the standard

Short circuit

250 °C

Conductor short-circuit rating

Voltage

10–380 kV

Medium voltage 10–50 kV AC, high voltage up to 380 kV AC, several hundred kV DC

Silane XLPE · 10 kV

Two materials, mixed 95 : 5 at the cable plant

Two compounds are made separately and mixed at the cable extruder.

A material

Grafted PE

  • LLDPE / LDPE 98% + DCP 0.1% + silane 1.5% + anti-oxidant
  • Loss-in-weight feeding, high-torque extruder, long L/D
  • Dryer and vacuum packing
B material

Catalyst masterbatch

  • LLDPE / LDPE 95.5% + DBTL 4% + anti-oxidant 0.5%
  • Loss-in-weight feeding, low-torque extruder, L/D 40

95% A + 5% B go into the XLPE cable extruder.

Peroxide XLPE · 35 kV

One material, held below its reaction temperature

The melt temperature must be controlled very well so the DCP does not react with the polymer.

  • LDPE
  • DCP
  • Anti-oxidant
  • Loss-in-weight feeding.
  • Two-stage extruders suit this compounding better, because they hold the melt temperature.
  • Cooling water for pelletizing must be clean, without positive or negative ions.
  • Dryer and vacuum packing system.
ModelDiameter (mm)Max. Speed (rpm)Motor (kW)L/DOutput (kg/h)
SAT6562.440013256400–500
SAT7571.440022056700–800
SAT959340031556900–1100
Conductor & insulation screens

Semiconductive compounds: one machine for every type

Peroxide and silane semiconductors are compatible with the two XLPE types. All kinds of semiconductive compound can be produced on the same machine.

Basic formula

  • PE / EVA
  • Carbon powder
  • DCP
  • Anti-oxidant
  1. Kneader
  2. Conical force feeding
  3. Single screw
  4. Air-cooling die face
ModelKneader Volume (Liter)Screw Diameter (mm)Screw Speed (rpm)Motor (kW)Output (kg/h)
K75-TDD1507515060110/75350–450
K110-TDD18011018060160/110550–600

PVC cable compounds

Plasticised PVC is commonly used as insulation and sheathing on electrical cables.

Tandem extruder for PVC cable compounding: twin screw first stage, single screw second stage
Tandem extruder for PVC cable compounding.

Tandem: twin screw to disperse, single screw to cool

The first stage is a co-rotating parallel twin screw extruder for dispersion and distribution; the second stage is a single screw extruder for cooling and pelletizing.

Basic formula

  • PVC60%
  • DOP20%
  • Calcined clay10–20%
  • CaCO₃0–10%
  • Heat stabiliser
  • Additives
ModelDiameter (mm)Max. Speed (rpm)L/DMotor (kW)Output (kg/h)
SAT52-TDD150R51.4/150500/9340/890/55250–350
SAT65-TDD180R62.4/180500/9340/8132/75500–600
SAT75-TDD200R71/200500/9340/8220/90800–1200
SAT95-TDD240R93/240500/9340/8355/1101700–2500

SolutionPVC compoundingsame tandem range

Halogen-free flame retardant (HFFR)

HFFR, low smoke zero halogen (LSZH) and low smoke and fume (LSF) are names for compounds used extensively in cable insulation. They are based on polyethylene or its co-polymers, with mineral fillers to make them flame retardant.

Basic formula
  • PE10%
  • EVA30%
  • ATH powder55%
  • Additives5%

Process 1Kneader

Kneader + twin screw + single screw

  1. Kneader
  2. Conical force feeding
  3. Twin screw
  4. Single screw
  5. Air-cooling die face

Process 2Loss-in-weight

Triple screw + single screw

  1. Loss-in-weight feeding
  2. Triple screw
  3. Single screw
  4. Air-cooling die face
ModelKneader Volume (Liter)Screw Diameter (mm)Screw Speed (rpm)Motor (kW)Output (kg/h)
K75-SAT65-TDD1807562.4/180500/75110/110/75400–500
K110-SAT75-TDD20011071.4/200500/75160/200/90700–800

Projects · XLPE

XLPE cable compounds on SAT95 with underwater pelletizing

Two XLPE cable compound lines, one for 35 kV peroxide XLPE in China and one for a client in India. Both run a SAT95 twin screw extruder into an underwater pelletizing system.

Extruder
SAT95
Output
800–1,500 kg/h
Pelletizing
Underwater
Feeding
Loss-in-weight
  1. Vacuum loader
  2. Buffer hopper
  3. Loss-in-weight
  4. Twin screw
  5. Filter
  6. Start-up valve
  7. Underwater pelletizing
  8. Dewater
  9. Classifier
  10. Fluidised bed
  11. Packing

Peroxide XLPE line for 35 kV cable 800 kg/h XLPE line, India

Peroxide XLPE for 35 kV cable, SAT95, China.

More cable compound lines

All compounding projects
India

800 kg/h XLPE cable compounding line

SAT95 · underwater800 kg/h

HFFR

500 kg/h HFFR cable compounding line

K75 · SAT75 · TDD180500 kg/h

Solution

PVC compounding

Tandem twin + single screwRigid & soft PVC

Get a quote

Tell us which cable compound you make — PE, silane or peroxide XLPE, semiconductive, PVC or HFFR — with its formula, filler loading and voltage class. We will propose the kneader or extruder stages, pelletizing and drying for that compound at your target output.

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  1. 01Compound, formula & voltage class
  2. 02Machine stages & pelletizing
  3. 03Drying, packing & layout
Souder Chen

Souder Chen

Head of Compounding Division

With USEON since 2008. Twin screw compounding, devolatilization and recycling lines.

souder.chen@useon.com+86 139 5186 5928

Cable Compounding

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