Power Cable

Engineer operating a cable extrusion line control panel

Introduction

Sai Extrumech power cable extrusion lines are built for low-voltage (LV), medium-voltage (MV) and high-voltage (HV) power transmission and distribution cables. Unlike thin-wall data cable lines, these handle large conductors and thick insulation walls, with the option of triple-layer extrusion for MV cables that require a semiconducting conductor screen, XLPE insulation, and an insulation screen applied in a single pass.

Lines are typically built around 90–150mm extruders at 24:1–28:1 L/D, with CCV (catenary continuous vulcanisation) or silane crosslinking for XLPE, and PVC handling for LV cables to IS 694 and IS 7098. Robust haul-off and large-drum take-up systems manage the weight of heavy-gauge cable, while precise melt-pressure control keeps insulation wall thickness and concentricity within IEC 60502 limits.

Applications:

  • Power grids and distribution networks
  • LV/MV building and substation feeders
  • Industrial plant power distribution
  • Renewable energy evacuation (solar, wind farms)

Why Sai Extrumech: We engineer the complete line — extruder, triple-layer crosshead, cooling and take-up — matched to your voltage class and conductor range, and supply replacement screws, barrels and tooling for existing lines.

Power Cable

Power Cable Construction

A finished power cable combines stranded copper or aluminium conductors, each covered with extruded insulation — PVC or XLPE — then laid up together and protected by an outer sheath. Precise, concentric insulation from the extrusion line ensures every core meets its voltage and temperature rating. Sai Extrumech builds complete power cable lines, including Sioplas HT-XLPE lines up to 33 kV.

Multi-core copper power cable cross-section

Key Features of Our Power Cable Extrusion Lines

Power cables carry electricity from LV distribution to MV networks, and each voltage class needs the right insulation and construction. Our power cable extrusion lines produce LV, MV and HV cables with PVC or XLPE insulation, single or multi-layer, up to 33 kV via our Sioplas triple-layer lines.

Key features:

  • LV, MV and HV power cable production
  • PVC and XLPE (Sioplas HT-XLPE up to 33 kV) insulation
  • Single, dual and triple-layer co-extrusion
  • Conductor screen, insulation and outer screen in one pass
  • Tight wall control for voltage and short-circuit ratings
  • See our Sioplas triple-layer line for MV cables
Cable extrusion production hall with copper wire spool

FAQS

What is an extrusion line for wire and cable?

 An extrusion line for wire and cable is a manufacturing system designed to produce high-quality wire and cable products. It typically involves feeding raw materials into an extruder, which melts and shapes them into the desired wire or cable form through a die.

What types of wire can be made in SAI’s extrusion line?
  • Extr line – Building wire
  • Industrial cable
  • Submersible cable
  • Power cable
  • Optical fibre cable
  • THN/LAN Cable
  • Solar cable
  • Sioplas cable 
  • Tandum cable
What are the key components of an extrusion line for wire and cable?

The key components of an extrusion line include:

  • Extruder
  • Cooling Trough
  • Take-Up and payoff.
  • Control System
  • Capstan
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 are the benefits of using Sai Extrumech's extrusion lines for wire and cable?

Benefits include:

  • High precision and efficiency.
  • Affordable units with excellent quality
  • Customizable solutions to meet specific needs.
  • Expert technical support and service.

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