Cable Manufacturing Process & Equipment Guide

This ultimate guide covers the entire cable manufacturing process from raw materials to finished product. As a leading China-based manufacturer of high-speed extrusion lines, stranding machines, and full turnkey cable production systems, DOSING provides real-world parameters, defect troubleshooting, and optimization strategies based on 2024–2026 deliveries to factories in Vietnam, Indonesia, Thailand, Malaysia, Philippines, and Turkey.

Ideal for cable manufacturers, engineers, procurement teams, and factory planners seeking to scale production, reduce scrap, and achieve <0.5% defect rates.

Explore the complete system:→ Extruder Production Line → Stranding/Bunching Machine → Wire Pay-off / Take-off → Drawing and Annealing Machine → Other Cable Equipment

(Modern high-speed extrusion lines – typical DOSING setup for data/power cables)

1. Cable Manufacturing System Overview

A modern cable line is an integrated chain:

Raw material preparation
Conductor drawing & annealing
Stranding / Bunching
Insulation extrusion (single/multi-layer)
Cooling & sizing
Quality inspection (online 100%)
Sheathing / Jacketing
Take-up, coiling, packaging

Coordination ensures line speeds up to 1200 m/min (data cables) with scrap <0.5%.

2. Conductor Drawing & Annealing

Conductor processing starts with rod breakdown to fine wire, followed by annealing for flexibility.

Typical parameters (DOSING multi-wire drawing lines):

Input rod: 8 mm copper → output 0.12–2.6 mm
Drawing speed: 25–40 m/s (multi-wire)
Annealing temperature: 400–550°C (continuous in-line)
Elongation control: 25–35% per die
Resistance stability: ±1% (oxygen-free copper + nitrogen protection)

Common issues & fixes:

Wire breakage: high back tension → active pay-off with load-cell feedback reduces breaks from 1/4h to 1/72h.
Surface oxidation: affects soldering → nitrogen shroud cuts oxidation 92%.
Uneven diameter: die wear → auto die compensation maintains ±0.002 mm.

Real data: A Malaysian client (2025) on our 16-head multi-wire drawer achieved 28 tons/day output, resistance variation <0.8%, monthly scrap <0.3%.

3. Stranding & Bunching Process

High-speed bunching affects conductor flexibility and resistance.

DOSING parameters (630–1250 series):

630 buncher: 2800 TPM, 350 m/min (7×0.20 mm)
Back-twist: 85–95% electronic adjustable (CAT8 needs high)
Tension: ±2 g accuracy

Issues & data:

Pitch uneven → resistance fail: servo direct-drive ±0.4% vs mechanical ±3.2%, rejection down from 4.7% to 0.6% (Turkey client).
Broken wire: pay-off surge → active system drops to 1/72h.

Philippines case (2025): 630 double-twist for CAT6: 500 kg/spool no breaks, pitch ±0.3 mm, maintenance ~RMB 1800/month.

(High-speed bunching machines in action)

4. Cable Extrusion Systems

Core process for insulation/jacketing.

Parameters:

PVC: 150–190°C zones
LSZH: 130–175°C
Line speed: 800–1200 m/min (CAT6A)
Melt pressure: 120–280 bar, stability ±5 bar

Defects & fixes:

Eccentricity: auto crosshead → from 1.8% to 0.12% scrap (Thailand).
Bubbles: dual drying → waste <0.5%.

Vietnam case (2025): 1200 m/min line: 21-day run, scrap 0.37%, 0.38 kWh/kg

(Extrusion line examples – cooling trough visible)

5. Cooling & Water Trough Systems

Controls shrinkage & diameter.

Configuration:

Gradient: 65–75°C → 40–50°C → 20–25°C (±0.5°C)
Length: 24–72 m
Flow: turbulent 2.5–3.5 m/s

Data: Gradient system → shrinkage 0.8–1.2% vs 2.8–3.5%. Diameter fluctuation ±0.008 mm.

Indonesia MV cable: Complaints from 11/month to 0 for 18 months.

(Note: Cooling images from search were not perfectly matched – suggest factory photos of troughs.)

6. Quality Inspection & Spark Testing

Systems: Sikora/X-ray diameter, 15 kV spark (30 μm pinhole detect), lump detector 5 μm.

Data: Vietnam (2025): shipped defect 11 ppm vs 280 ppm manual. Spark caught 47 pinholes/month, saved ~USD 180k claims.

7. Defects & Troubleshooting Summary

Surface roughness → melt instability
Eccentric → die centering
Cracks → rapid cooling

Strategies: PID control, predictive maintenance, material QC.

8. Smart Manufacturing & Turnkey Solutions

Integrate IoT monitoring, AI defect detection, predictive maintenance.

DOSING advantage: Full turnkey – design, install, train, achieve 35% efficiency gain (Vietnam case).

Conclusion & Next Steps

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Contact:WhatsApp / Mob: +86 13829229053 Email: admin@dxcabletech.com

Address: Caopu Industrial Zone, Humen, Dongguan, China