Cable Compounding machine

GSmach is committed to providing advanced extruder for all kind of cable compounding:

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PE compounds are widely used in wires and cables for insulation and sheathing purposes. In fact, polyethylene compounds are among the most common forms of plastics. Polyethylene is a thermoplastic polymer consisting of long hydrocarbon chains of the base monomer (C2H4) and our PE compounds are generally based on polyethylene or co-polymers of polyethylene suitably modified to client specifications.


Basic Formula:

LDPE/LLDPE/MDPE/HDPE + color pigment/carbon black 2-5% + additives


Three Types of Process:

1) Kneader + Conical Force Feeding + Single Screw Extruder + Water Ring Pelletizing

Technical Specifications of Extruder:
Type Screw diameter (mm) Kneader Output(kg/h)
GS-100 100 35 200-300
GS-120 120 55-75 400-600
GS-150 150 110 800-1000
180 150 1000-1500

2) Mixer + Twin Screw Extruder + Water Ring Pelletizing 

3) Loss-in-weight Feeding + Twin Screw Extruder + Water Ring Pelletizing


Crosslinkable PE (XLPE) Insulation Compounds

Polyethylene has been and still is used as a cable insulant, but, as a thermoplastic material, its applications are limited by thermal constraints. Crosslinking improves the elevated-temperature properties of the base polymer. The effect of the cross-linking is to inhibit the movement of molecules with respect to each other under the stimulation of heat and this gives the improved stability at elevated temperatures compared with the thermoplastic materials. This permits higher operating temperatures, both for normal loading and under short-circuit conditions, so that an XLPE cable has a higher current rating than its equivalent PVC counterpart. XLPE has one of the best water resistance and low permeability capacities and abilities.

Almost all cross-linkable polyethylene compounds (XLPE) for wire and cable applications are based on LDPE. XLPE-insulated cables have a rated maximum conductor temperature of 90 °C and an emergency rating up to 140 °C, depending on the standard used. They have a conductor short-circuit rating of 250 °C. XLPE has excellent dielectric properties, making it useful for medium voltage-10 to 50 kV AC, and high voltage cables-up to 380 kV AC-voltage, and several hundred kV DC.


There are two type XLPE:

  • Silane XLPE for 10kV cable
  • Peroxide XLPE for 35kV cable

Semiconductor Layer compatible with these two types of XLPE:

  • Silane semiconductor
  • Peroxide semiconductor

All kind of semiconductor compounds can be produced by the same machine.


Silane XLPE for 10kV Cable

1) Basic formula

A material: LLDPE/LDPE 98% + DCP 0.1% + Silane 1.5% + Anti-oxidant
B material: LLDPE/LDPE 95.5% + DBTL 4% + Anti-oxidant 0.5%
Mix 95% of A and 5% B material for the XLPE Cable extrusion

2) Process

① For A material: loss-in-weight feeding and High torque extruder with long L/D.

Need dryer and vacuum packing system.

② For B material: loss-in-weight feeding and Low torque extruder with 40 L/D.


Peroxide XLPE for 35kV Cable

1) Basic formula

LDPE + DCP+ Anti-oxidant


2) Process

Loss-in-weight feeding.

The melt temperature should be controlled very well to avoid the DCP reacting with polymer. So, two stage extruders are more suitable for this kind of compounding.

The cooling water for pelletizing system should be clean without any positive and negative ions

This needs a dryer and vacuum packing system.


Peroxide/Silane Semiconductor Compounds


1) Basic formula

PE/EVA + carbon powder + DCP + Anti-oxidant


2) Process

The same machine can be used for all types of semiconductors.

Kneader + conical force feeding +single screw extruder + air cooling die face pelletizing.


PVC Compounds for Cable

Polyvinyl chloride is the third-most widely produced synthetic plastic polymer, after polyethylene and polypropylene. It is produced by polymerization of the vinyl chloride monomer (VCM) .

PVC’s relatively low cost, biological and chemical resistance and workability have resulted in it being used for a wide variety of applications. Plasticized PVC is commonly used as insulation & sheathing on electrical cables.


Basic Formula:

PVC 60% + DOP 20% + Calcined Clay 10-20% + CaCO3 0-10% + Heating Stabilizer + Additives


Tandem Extruder for PVC Compounding:

The first stage is co-rotating parallel twin screw extruder for dispersion and distribution.
The second stage is single screw extruder for cooling and pelletizing.


Technical Specifications of Extruder:

Type Motor Power Rotate Speed Output(kg/h)
GS50-100 37-55/22-45 500-600/60-90 200-300
GS65-150 55-75/45-55 500-600/60-90 400-500
GS75-180 75-132/75-90 500-600/60-90 600-800
GS95-200 250-315/90-132 400-500/60-90 1000-1500

Halogen Free Flame Retardant (HFFR)

Halogen free flame retardant (HFFR), low smoke zero halogen (LSOH), low smoke and fume (LSF) are all names associated with compounds that are used extensively in the cable insulation. These compounds are generally based on polyethylene or co-polymers of polyethylene with the addition of mineral fillers to impart flame retardant properties.


Basic Formula:

PE 10% + EVA 30% + ATH powder 55% + Additive 5%


Two Types of Process:

1) Kneader + Conical Force Feeding + Twin Screw Extruder + Single Screw Extruder + Air Cooling Die Face Pelletizing
Technical Specifications of Extruder:
2) Loss-in-weight Feeding + Triple Screw Extruder + Single Screw Extruder + Air Cooling Die Face Pelletizing
Technical Specifications of Extruder:
Type Kneader Screw Dia(mm) Output(kg/h)
GS50-100 55 50.5/100mm 200-300
GS65-150 75 62.4/150mm 400-500
GS75-180 110 71/180mm 600-800
GS95-200 150 93/200mm



Technical Specifications of Extruder:(Triple Screw Extruder )

Type power Screw Dia(mm) Output(kg/h)
GS36 18.5-30 36mm 50-150
GS52 75-90 52mm 250-800
GS65 90-160 65mm 500-1000
GS75 132-250 75mm


GS95 200-315 95mm


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