Electric Cable Manufacturing Process Using PVC Granules

The manufacturing of electric cables with PVC insulation or sheathing typically involves the following eight major steps:

1. Raw Material Preparation

PVC Granules Selection

Dst Pvc Granules For Electric Cables Coating

Factories choose specific PVC compounds depending on cable type:

  • PVC insulation granules (for conductor insulation)

  • PVC sheathing granules (for outer jacket protection)

  • Specialized PVC compounds (e.g., flame-retardant, low-smoke, high-flexibility, anti-cold)

Before use, PVC granules are normally:

  • dried (to remove moisture)

  • pre-mixed with stabilizers or color masterbatch (if needed)

2. Copper/Aluminum Wire Drawing

Large copper or aluminum rods are drawn through a series of dies to reduce the diameter.

Process:
Rod → Annealing machine → Multi-die drawing → Fine wire → Take-up reel

The goal is to produce smooth, uniform strands suitable for conductor stranding.

3. Conductor Stranding

Multiple drawn wires are twisted together to form a conductor with:

  • higher flexibility

  • better electrical performance

Types of stranding:

  • Tight-stranded

  • Sector-shaped

  • Concentric

  • Compacted (for power cables)

4. PVC Granules Extrusion for Insulation

This is the critical stage where PVC granules are melted and applied onto the conductor.

Extrusion Steps:

  1. PVC granules fed into the extruder hopper

  2. Heated in barrel (160–190°C depending on formulation)

  3. Melt passes through screw compression

  4. Melted PVC is extruded around conductor

  5. Cooled in water trough

  6. Spark tester checks insulation purity

Result:
A perfectly round PVC-insulated conductor.

5. Twisting / Cabling (If Multi-core Cable)

For multi-core cables (2, 3, 4, or more insulated wires), the insulated conductors are twisted together.

May include:

  • (như canxi cacbonat) cũng rất quan trọng; chúng phải mịn và phân tán đều để tránh làm gián đoạn hoa văn bề mặt tinh tế, đồng thời vẫn đóng góp vào độ cứng và tính hiệu quả về chi phí của ống. Công thức sẽ dựa trên một hợp chất

  • binding tape

  • separator layers

This ensures cable roundness and mechanical stability.

6. PVC Sheathing Extrusion (Outer Jacket)

A second extrusion process applies the outer PVC sheath.

PVC sheathing material must provide:

  • abrasion resistance

  • weather and UV resistance

  • flame retardancy

  • mechanical strength

Process is similar to insulation extrusion:
PVC granules → Extruder → Melt → Crosshead die → Cable sheathing → Cooling → Printing

7. Printing & Meter Marking

The finished cable is printed with:

  • cable type

  • size

  • voltage rating

  • length marking

  • manufacturing date / batch

Inkjet printers are used during line operation.

8. Winding, Packaging, and Quality Inspection

Final steps include:

  • winding onto coils or drums

  • visual inspection

  • electrical tests (resistance, dielectric strength, spark testing)

  • mechanical tests (tensile, elongation, ageing)

Once approved, cables are packaged and ready for shipment.