extrusion
Cable & Wire Extrusion Line
High-performance extrusion lines for consistent insulation, sheathing, and high-speed cable production.
A complete extrusion system
Supertec's Cable & Wire Extrusion Line is a production-ready system for high-speed insulation and sheathing of copper and aluminium conductors. The line is configured around the material, conductor range, target speed, and plant layout of each customer.
The integrated extruder, crosshead, cooling trough, capstan, and take-up system are engineered to work as one reliable production line, reducing compatibility issues and simplifying commissioning.
overview
Machine overview.
The Cable & Wire Extrusion Line from Supertec Machines is a complete, production-ready system engineered for high-speed insulation and sheathing of copper and aluminium conductors. Designed to handle a wide range of conductor sizes — from fine wires as small as 0.5 mm² to heavy-duty power cables up to 400 mm² — the line delivers consistent wall thickness, concentricity, and surface finish at speeds that meet modern production demands.
Every component of the extrusion line is designed in-house and manufactured at our Faridabad facility. From the extruder and crosshead to the cooling trough, capstan, and take-up system, each element is engineered to work together as a unified, reliable production line. This integrated approach eliminates the compatibility challenges that arise when sourcing equipment from multiple vendors.
Whether you are producing building wire, flexible cables, power cables, or specialty conductors, the Cable & Wire Extrusion Line can be configured to meet your exact material, speed, and dimensional requirements. Supertec's engineering team works closely with each customer to specify the right extruder size, screw geometry, crosshead design, cooling configuration, and downstream equipment for the target application.
Cable & Wire Production in Action
150 mm Cable Extrusion line for Power Cable.
Key Features
Thoughtfully engineered for precision, reliability and lasting performance.
Engineered for performance.
High-Speed Production
Line speeds up to 800 m/min for fine wire insulation and up to 200 m/min for power cable sheathing, enabling high-volume output without compromising quality.
Precision Temperature Control
Individually zoned PID temperature controllers across all barrel, die, and crosshead zones maintain ±1°C accuracy for consistent melt quality.
Configurable Extruder Range
Extruder sizes from 25 mm to 150 mm diameter with optimized L/D ratios and screw geometries for PVC, XLPE, PE, LSZH, and specialty compounds.
Integrated Diameter Control
Laser-based online measurement with closed-loop feedback to the line speed controller ensures consistent wall thickness and dimensional accuracy.
Quick-Change Crosshead
Modular crosshead design enables rapid tooling changes with minimal downtime, supporting a wide range of conductor and cable sizes.
Advanced Cooling System
Vacuum-assisted cooling troughs with adjustable water flow and temperature control, optimized for different insulation materials and cable sizes.
Robust Mechanical Design
Heavy-duty frame construction with precision-machined components ensures long service life and minimal maintenance requirements.
Customizable Configuration
Every line is engineered to customer specifications — extruder size, line layout, downstream equipment, and automation level can be tailored to specific production needs.
Precision engineered · Built for industry
Applications
Built for every cable.
Building & Housing Wire
Single and multi-core PVC insulated wires for residential, commercial, and industrial electrical installations.
Power Cables
Medium and low voltage power cables with PVC, XLPE, or PE insulation for power distribution and transmission networks.
Flexible Cables
Multi-strand flexible cables for industrial machinery, appliances, and portable equipment applications.
Control & Instrumentation Cables
Multi-pair and multi-core control cables for process automation, instrumentation, and signaling systems.
Communication Cables
Telephone and data communication cables with precision insulation for consistent electrical performance.
Automotive & Specialty Wires
Automotive primary wire, appliance wire, and specialty conductor insulation for demanding environments.
Precision engineeredSupertec Machines
technical specifications
Extruder Specifications
- Screw diameter
- 25 mm – 150 mm
- L/D ratio
- 20:1 – 30:1
- Drive motor
- AC variable frequency drive
- Barrel material
- Nitrided alloy steel
- Heating zones
- 3 – 6 zones (size dependent)
- Temperature control
- PID with ±1°C accuracy
Line Performance
- Maximum line speed
- Up to 800 m/min
- Conductor range
- 0.5 mm² – 400 mm²
- Insulation thickness
- 0.3 mm – 5 mm
- Production output
- Up to 2,500 kg/hr
- Materials supported
- PVC, XLPE, PE, LSZH, Nylon
Downstream Equipment
- Cooling trough
- Vacuum-assisted, adjustable
- Diameter gauge
- Laser-based, online
- Capstan type
- Belt or wheel, variable speed
- Take-up system
- Single / dual, auto-traverse
- Spark tester
- Inline, adjustable voltage
Quality Assurance & Testing
Every Cable & Wire Extrusion Line undergoes rigorous quality testing before dispatch. Critical dimensions, surface finishes, and alignment tolerances are verified at each stage of assembly. The complete line is test-run at our facility to confirm mechanical performance, temperature stability, and control system responsiveness.
Supertec follows ISO-aligned quality management practices throughout the manufacturing process. Raw materials are inspected upon receipt, machining operations are verified with precision instruments, and final assemblies are tested against customer-approved specifications before shipping.
Installation & Commissioning
Supertec provides comprehensive installation and commissioning support for every extrusion line. Our experienced field engineers handle mechanical installation, electrical connections, control system setup, and initial production trials at the customer's site.
Training is included as part of the commissioning process. Operators and maintenance staff receive hands-on instruction covering line operation, parameter optimization, preventive maintenance procedures, and basic troubleshooting — ensuring your team is production-ready from day one.
advantages
Thoughtfully engineered for precision, reliability and lasting performance.
Engineered for performance.
Turnkey Solution
Complete line from pay-off to take-up, designed, manufactured, and commissioned by one team — no multi-vendor coordination.
40+ Years of Experience
Since 1984, Supertec has been building cable machinery for manufacturers across India and internationally, refining designs based on real production feedback.
Full Customization
Every line is configured to the customer's specific conductor types, insulation materials, target speeds, and plant layout requirements.
Local Manufacturing & Support
Designed and built in Faridabad, India with responsive after-sales support, spare parts availability, and on-site commissioning assistance.
Precision engineered · Built for industry
FAQs
Frequently asked questions.
Helpful details about this machine, its capabilities, and applications.
What does a cable and wire extrusion line do?
What conductor range can the described line handle?
Which insulation materials are supported?
Can the line be configured for different cable products?
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