Solar power capacity in India is growing faster than almost any other sector. Behind every solar panel installation is a cable network — and behind every solar cable is a precisely engineered extrusion line.
Sai Extrumech designs and manufactures solar cable extrusion lines for producers of DC solar cables, photovoltaic wiring, and EV charging cables across India and internationally.
What is a Solar Cable?
A solar cable (also called a photovoltaic cable or PV cable) is a single-core or multi-core cable designed to carry DC current between solar panels, inverters, and battery storage systems.
Solar cables must withstand:
- UV radiation — direct outdoor sunlight exposure for 25+ years
- High temperatures — surface temperatures on rooftops can exceed 80°C
- Weather exposure — rain, humidity, dust, and ozone
- DC voltage — typically 1000V or 1500V DC for utility-scale installations
- Mechanical stress — flexing during installation and wind movement
To meet these requirements, solar cables are typically insulated with XLPE (cross-linked polyethylene) or LSZH (low-smoke zero-halogen) compounds — both of which require specific extrusion line configurations.
Sai Extrumech Solar Cable Extrusion Lines
Our solar cable extrusion lines are engineered for the specific demands of UV-stabilised and XLPE compound processing. Each line is custom-designed to your conductor range, output target, and compound specification.
Standard Configuration
Extruder: Single screw extruder, 45mm–90mm diameter, 24:1 L/D (for XLPE) or 28:1 L/D (for LSZH compounds)
Crosshead: Fixed centre or manual centre crosshead with precision die-tip sets for conductor sizes 1.5mm² to 300mm²
Cooling: Multi-pass cooling trough, 6–12 metres, with temperature-controlled water circulation
Haul-off: Dual caterpillar haul-off with constant tension control
Take-up: Automatic single or dual bobbin take-up with traverse mechanism
Line speed: 10–80 metres per minute depending on insulation wall thickness and conductor size
Optional Add-ons
- Spark tester (online dielectric integrity testing)
- Diameter gauge (laser measurement for real-time OD monitoring)
- Ink-jet printer for cable marking
- Silane crosslinking bath (for silane XLPE process)
Key Technical Considerations for Solar Cable Production
XLPE Processing
XLPE compound for solar cables is typically processed via the silane crosslinking method (moisture cure), which requires careful temperature control and a short residence time screw (20–24:1 L/D). Our lines include temperature-zoned barrels with PID controllers on each zone.
UV Stabilisation
UV-stabilised LSZH compounds for solar cables contain carbon black and other additives that are abrasive. We recommend bimetallic screws and barrels for these compounds to extend service life.
Concentricity Control
Solar cable insulation concentricity is specified to tight tolerances in IEC 60227 and IEC 62930. Our manual centre crossheads allow real-time concentricity adjustment during production without stopping the line.
Applications
Solar cable extrusion lines from Sai Extrumech are suitable for:
- DC solar cables (1.5mm² – 300mm²)
- EV charging cables (Type 2, CCS, CHAdeMO configurations)
- Photovoltaic string cables
- Battery interconnect cables
- Solar farm trunk cables
Why Choose Sai Extrumech for Your Solar Cable Line?
- 25+ years manufacturing extrusion lines for the Indian cable industry
- In-house design and manufacturing — no third-party sub-assemblies
- Custom engineering for your conductor range and compound
- After-sales support and spare parts supply from Faridabad
- Lines operational in India, UAE, South Africa, UK, and Bangladesh
- Academic collaboration with IIT Delhi and BITS Pilani for process R&D
Get a Quote
Tell us your production requirements and we will design a solar cable extrusion line around your specific needs.
Required information:
- Conductor size range (mm²)
- Insulation material (XLPE, LSZH, PVC)
- Target line speed
- Bobbin/drum size
- Required certifications (IEC 62930, IS 694, etc.)
👉 Contact our Engineering Team
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