Cable and Wire Extrusion Line

Sai Extrumech designs and manufactures cable and wire extrusion lines for producers across residential, industrial and infrastructure applications. With over 25 years of experience, our machines are built to handle a wide product range — building wire, control cable, power cable, instrumentation cable and optical fibre cable — with consistent insulation quality and high line speed.

Each wire extrusion line is configured to the customer’s conductor size, insulation material and output requirement. We offer single, dual and triple-layer extrusion machine setups, so whether the requirement is a compact cable extrusion line for lower-volume production or a high-speed wire and cable extrusion machine for continuous industrial output, the configuration is built around the application — not adapted from a fixed template.

With in-house design and manufacturing, Sai Extrumech works as a complete cable extruder manufacturer — from initial machine specification through to after-sales support once the line is running.

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Cable and Wire Extrusion Line Configurations

Every wire and cable application has different production requirements. The required extruder size, layer configuration and line setup depend on factors such as cable type, conductor size, insulation material, required output and production speed.

At Sai Extrumech, we offer flexible cable and wire extrusion line configurations, including different extruder sizes and single-, dual- and triple-layer systems. The table below helps you understand the available configurations and identify a suitable setup for applications such as building wire, control cable, instrumentation cable, optical fibre and power cable.

Type	Extrusion Line	Building Wire	Control Cable	Instrumentation Cable	Optical Fiber	Power Cable	Medical Tubing
Single Layer	25mm	❌	❌	❌	❌	❌	✅
Single Layer	30mm	❌	✅	✅	❌	❌	✅
Single Layer	45mm	✅	✅	✅	✅	❌	✅
Single Layer	50mm	✅	✅	✅	✅	❌	❌
Single Layer	65mm	✅	✅	✅	✅	✅	❌
Single Layer	80mm	✅	✅	✅	✅	✅	❌
Single Layer	10mm	❌	✅	✅	❌	❌	❌
Single Layer	120mm	❌	✅	✅	✅	✅	❌
Dual Layer	45mm-25mm	✅	❌	✅	✅	✅	✅
Dual Layer	50mm-30mm	❌	❌	✅	❌	❌	✅
Dual Layer	65mm-45mm	✅	✅	✅	✅	✅	❌
Dual Layer	80mm-50mm	✅	✅	✅	✅	✅	❌
Dual Layer	100mm-65mm	❌	✅	✅	✅	✅	❌
Dual Layer	120mm-65mm	❌	✅	✅	✅	✅	❌
Triple Layer	25-45-30mm	✅	❌	❌	❌	❌	✅
Triple Layer	30-65-45mm	✅	❌	❌	❌	❌	✅
Triple Layer	45-80-50mm	✅	❌	❌	❌	❌	✅

Cable and Wire Extrusion Line for Different Applications

Different wire and cable products require different extrusion configurations, materials and production conditions. Sai Extrumech offers application-specific extrusion line solutions for various wire and cable manufacturing requirements, from building wires and control cables to power, solar and other specialized cables.

Explore the suitable extrusion solution for your application below.

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Get in touch with Sai Extrumech for the right extrusion solution for your wire and cable manufacturing requirements.

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What is a cable and wire extrusion line used for?

A cable and wire extrusion line applies insulation and outer sheathing onto a bare conductor, turning it into a finished, usable wire or cable. Depending on how it’s configured, the same basic process can produce building wire, control cable, power cable, instrumentation cable, optical fibre cable and other specialised wire and cable products.

How does a wire and cable extrusion machine work?

A wire and cable extrusion line runs the conductor through several stages in one continuous process:

Pay-off: The bare conductor unwinds from a spool and feeds into the line.
Hopper: Raw insulation material (like PVC, PE or XLPE) is loaded and fed into the extruder.
Screw & Barrel: Inside the extruder, the material is heated, melted and pushed forward under pressure.
Crosshead: The molten material is redirected around the moving conductor.
Tip & Die (Nozzle): This shapes and applies an even layer of insulation onto the conductor.
PLC Control Panel: Monitors and controls temperature, speed and output across the entire line.
Cooling Trough: The freshly insulated wire passes through water to cool and set the coating.
Spark Tester: Checks the insulation for any faults or weak spots.
Capstan & Caterpillar: These pull the wire through the line at a steady, consistent speed.
Take-up: The finished wire is wound onto a spool, ready for dispatch.

What sizes of extruders does Sai Extrumech offer?

Sai Extrumech manufactures extruders starting at 25mm for smaller conductors, up to 120mm for heavier cables, along with dual and triple-layer configurations for products that need more than one layer applied in a single pass.

Can the extrusion line be customised for my specific cable requirement?

Yes, every cable and wire extrusion line from Sai Extrumech is built around the customer’s specific cable requirements. Conductor size, insulation material and target output all shape the final configuration, so the machine you get is engineered for your product — not a fixed, one-size-fits-all setup.

Can Sai Extrumech customize extrusion lines for specific requirements?

Yes, Sai Extrumech offers customized extrusion lines tailored to meet specific customer requirements. We work closely with our clients to understand their needs and design solutions that optimize performance and efficiency.

What's the difference between single, dual and triple-layer lines?

A single-layer line applies one coat of insulation in a single pass. Dual- and triple-layer lines apply two or three layers — such as insulation plus an outer sheath — in one continuous run, which is common for power cable and building wire.

Which materials can be processed on Sai Extrumech's cable and wire extrusion lines?

It depends on the application, but our lines are built to handle a range of insulation and sheathing materials—PVC, PE, XLPE, LSZH, and other compounds.

How long has Sai Extrumech been in cable and wire extrusion machine manufacturing?

Sai Extrumech has been in cable and wire extrusion machine manufacturing for over 25 years. In that time, we’ve worked with a wide range of wire and cable manufacturers across India, which has shaped how we approach new configurations — we’ve usually seen something close to it before

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Cable and Wire Extrusion Line Manufacturer