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High Voltage Catenary Continuous Vulcanizing

Nearest Maillefer contacts for USA

KN Manufacturing Solutions LLC

Fiber Optic

5464 Woodrun Ct
GA 30517 Braselton

Tel: +1 770 967 1770

Cell: +1 404 202 9655

Fax: +1 770 967 1770

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TDC (Technical Development Corporation)

Wire & Cable

11845 Vanstory Drive
NC 28078 Huntersville

Tel: +1-770-337-3347

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Maillefer North America

Pipe & Tube

Phipps Bend Industrial Park<br /> 402 Phipps Bend Road
TN 37873 Surgoinsville

Tel: +1 423 817 2440

Fax: +1 423 212 0131

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Maillefer North America

Wire & Cable

4012 Washington Drive<br /> Upper Chichester
PA 19061 Philadelphia

Tel: +1 920-215-6628

Continuous high-speed insulation and vulcanizing of a wide range of power cables, from medium to extra high voltage. By using our insulation technology, you can produce high-quality cable with a limited investment.

How to get more value?

Right capacity

How easily can you respond to market changes? Is your answer profitable enough for you? With us you can choose from three different capacity levels without compromising availability or quality of your production solution. Proactive services enhance your operations even further.

Lower production costs

Is material-efficiency important to you? Our technologies guarantee excellent centricity and high stability of your products. State-of-the-art extruders and crossheads save material and minimize scrap in your production. Versatile raw materials, that suit to your production in quality, quantity and price, are applicable on several technologies.

Sustainable products

How sustainable are your products? Purity and smoothness in layers are in the core of our solution development. With us, you can deliver more durable products that are easy to install and secure to use.

Our Way of Working

  1. Production solution iteration

    We simulate possible line configurations for different production speeds and spaces for you

  2. Installation and production start

    We supervise the installation at your premises to answer any questions which may arise. In each delivery, we do the line set-up to ensure that all our promises are fulfilled in the delivery.

  3. Investment renewal

    We help you to achieve the best production value throughout your investment lifecycle. There are several performance and upgrade services to explore new business opportunities.

Compact quality solution for more sustainable production. Affordable investment that is easy to start and maintain in different production environments.

EPL 50Enter

Affordable choice, easy start

Are you new player in HV cable manufacturing and would like to have immediate production from day one?

Choose our EPL 50 /Enter, an affordable investment that is easy to start and maintain in different production environments. It offers

  • Manufacturing start with minimal investment
  • User-friendliness and reduced maintenance minimize operation costs
  • Minimum scrap

What you get

Immediate production from the very first day

  • Reliable, worry-free medium and high voltage cable production
  • Top quality medium and high voltage cable
  • Leading technology proven worldwide

Performance

Theoretical yearly capacity

500 km, 800 mm2 Cu 110 kV

Remove risk from the equation

With our Entry Heat Treatment, excellent roundness and concentricity can be achieved in your catenary continuous vulcanizing line without heavy rotation and the risk of damaging sensitive milliken conductors.

Typical line composition

  • FPO 20LV Floor Pay-off
  • OTC Optical Traverse Control
  • QCS 3000 Quick Conductor Splicing
  • KS 140 Cable Clamp
  • MHE DB 2000LV Accumulator
  • TPU 2500 Turn Pulley
  • BCA 21 Caterpillar
  • MXI 80-20D Air Cooled Extruder
  • MXI 175-24D Air Cooled Extruder
  • MXI 80-20D Air Cooled Extruder
  • THX 50/90 Triple Crosshead
  • X-RAY 8000 Measuring System
  • SB 150, CCV Splice Box
  • EHT Entry Heat Treatment
  • Curing tube DN 200, 10 zones
  • NCS Nitrogen Circulation System
  • Cooling Tube, 120 m
  • ES 150 SS End Seal
  • LOWCS Light Open Water Cooling System
  • KLH-HD Cable Twister
  • BCA 21 Caterpillar
  • TPU 2500 Turn Pulley
  • BCA 12 Caterpillar
  • FTU 20LV Floor Take-up
  • FTU 20LV Floor Take-up
  • Line Control Autocure 4.1

Specifications

Voltage range 10 – 110 kV
Conductor cross section Cu mm2 25 – 1000
Conductor cross section Al mm2 35 – 1000
Conductor type Round, solid, stranded
Insulation layer thicknesses  
Conductor screen (mm) 0.4 – 2.0 mm
Insulation (mm) 3.4 – 21 mm
Insulation screen (mm) 0.4 – 2.0 mm
Max. cable weight (kg/m) 12
Max. Cable diameter (mm) 75
Lenght of typical line (m) 215
Extruder platform height (m) 20.8
Constructive line speed (m/min) 50

Value packages

Production Capacity

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

High Output Value Package for HV/EHV CCV Lines

High and extra high voltage cables have important insulation thicknesses, and considerable insulation weight is supported by a small conductor. If the viscosity of the material close to the conductor decreases, as is the case when the temperature increases rapidly, significant drooping occurs and the insulation will be off-centered. In addition to eliminating the drooping effect, our patented method increases heating and cross-linking capacity, and thus line speeds, in catenary continuous vulcanizing lines for medium, high and extra high voltage cable production.

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors and high voltage (HV) Milliken conductors up to 3000 mm².

Production Cost

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors and high voltage (HV) Milliken conductors up to 3000 mm².

Product Quality

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

Clean Run Value Package

While your compound suppliers provide clean XLPE insulation compounds, with our clean-run value package these compounds are kept clean. In fact, they are made even cleaner through the material conveying from the package to the extruder.

Round Value Package Basic

The cooling circulation of nitrogen shrinks the outer surface of the insulation, thereby forcing the insulated core into its round shape. This process enables a catenary line with moderate rotation to produce cables with thick walls.

Lean and proven production solution for changing market needs. Good upgradability and versatile product range guarantee a technical fit for the future.

EPL 50Extend

Quality medium and high voltage XLPE cables

Are you looking for a high-performing insulation and vulcanizing process which is easy to install and performs reliably?

Our EPL 50 Extend line emphasizes reliability and flexibility when producing medium and high voltage cables and offers

  • High-quality results
  • Fast line production
  • Minimized material costs and easy installation

What you get

Cable that serves you well by meeting the end user's requirements

  • Top-quality medium and high voltage cable
  • High-performance medium and high voltage cable production
  • Leading technology proven worldwide

Performance

Theoretical yearly capacity

200 km, 1000 mm2 Cu 220 kV

Remove risk from the equation

With our Entry Heat Treatment, excellent roundness and concentricity can be achieved in your catenary continuous vulcanizing line without heavy rotation and the risk of damaging sensitive milliken conductors.

Typical line composition

  • AVR 20.16-36 Portal pay-off
  • AVR 20.16-36 L2 Portal pay-off
  • KS160 Vertical cable clamp
  • SL 120 Dancer
  • MHE DB 2000LV/5+6/120m Accumulator
  • HSC 2000 C High Stability Capstan
  • EFD 100 Conductor Preheater
  • NXW 80-20D Water cooled extruder
  • NXW 175-24D Water cooled extruder
  • NXW 100-20D Water cooled extruder
  • NXW Cooling unit for extruder group
  • THX 70/130 Triple crosshead
  • IWT 300 Integrated Water Tempering unit
  • X-RAY 8000 Diameter, Wall thickness and Eccentricity measuring system
  • PDI Isolator
  • Gravity feeding
  • Semicon material drying and conveying
  • SB 150 Splice box
  • EHT Entry Heat treatment
  • Curing tube CDCC, DN 250-8 zones
  • Siccon 6000 Catenary Control System
  • THS Tube heating system
  • N2P Nitrogen Pressure Control System
  • NCS Nitrogen Circulation System
  • Cooling Tube DN 200-90 m
  • OWCS Open Water Cooling System
  • ES 150 DS Douple End seal
  • KLH-HD Cable Twister
  • BCA 30 Caterpillar
  • TPU 3000 Turn Pulley
  • SL 120 Dancer
  • BLMD 2000 Belt length measuring system
  • BCA 15 Caterpillar
  • TUT 20.16-36 L2 Portal take up
  • TUT 20.16-36 Portal take up
  • Autocure 4.1 S7 Line Control
  • Optional component

    By Product Separator

Specifications

Voltage range 10 – 220 kV
Conductor cross section Cu mm2 35 –2000
Conductor cross section Al mm2 50 – 2000
Conductor type Round, solid, stranded
Insulation layer thicknesses  
Conductor screen (mm) 0.4 – 2.0 mm
Insulation (mm) 3.4 – 25
Insulation screen (mm) 0.4 – 2.0 mm
Max. cable weight (kg/m) 25
Max. Cable diameter (mm) 120
Lenght of typical line (m) 180
Extruder platform height (m) 16
Constructive line speed (m/min) 25

Value packages

Production Capacity

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

High Output Value Package for HV/EHV CCV Lines

High and extra high voltage cables have important insulation thicknesses, and considerable insulation weight is supported by a small conductor. If the viscosity of the material close to the conductor decreases, as is the case when the temperature increases rapidly, significant drooping occurs and the insulation will be off-centered. In addition to eliminating the drooping effect, our patented method increases heating and cross-linking capacity, and thus line speeds, in catenary continuous vulcanizing lines for medium, high and extra high voltage cable production.

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors and high voltage (HV) Milliken conductors up to 3000 mm².

Production Cost

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors and high voltage (HV) Milliken conductors up to 3000 mm².

Product Quality

Clean Run Value Package

While your compound suppliers provide clean XLPE insulation compounds, with our clean-run value package these compounds are kept clean. In fact, they are made even cleaner through the material conveying from the package to the extruder.

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

Round Value Package Basic

The cooling circulation of nitrogen shrinks the outer surface of the insulation, thereby forcing the insulated core into its round shape. This process enables a catenary line with moderate rotation to produce cables with thick walls.

Royal road to demanding deliveries with the lowest total cost of ownership. High output solution to explore the market in the front row.

EPL 50Explore

Quality high and extra high voltage XLPE cables 

Are you searching for a fast insulation and vulcanizing technology with a headache-free installation process?

Our EPL 50 Explore line is designed for reliable, high-quality production of high and extra high voltage cables, and offers

  • Premium level production
  • High line speeds
  • Reduce material costs by limiting waste

What you get

Cable that fulfills all of the end user's requirements

  • Excellent high and extra high voltage cable quality
  • Superior high and extra high cable production
  • Reliable extra high voltage production without building a tower

Performance

Theoretical yearly capacity

250 km, 1000 mm2 Cu 220 kV

Remove risk from the equation

With our Entry Heat Treatment, excellent roundness and concentricity can be achieved in your catenary continuous vulcanizing line without heavy rotation and the risk of damaging sensitive milliken conductors.

Typical line composition

  • FBO 30.16-40 Floor pay-off
  • FBO 30.16-40 Floor pay-off
  • KS160 Vertical cable clamp
  • SL 150 Dancer
  • MHE DB 2000LV/5+6/160m Accumulator
  • BCA 15 Vertical Caterpillar
  • HSC 3500 C High Stability Capstan
  • EFD 100 Conductor Preheater
  • NXW 80-20D Water cooled extruder
  • NXW 200-24D Water cooled extruder
  • NXW 100-20D Water cooled extruder
  • NXW Cooling unit for extruder group
  • THX 70/150 Triple crosshead
  • IWT 300 Integrated Water Tempering unit
  • X-RAY 8000 Diameter, Wall thickness and Eccentricity measuring system
  • PDI Isolator
  • Gravity feeding
  • Semicon material drying and conveying
  • SB 200 Splice box
  • EHT Entry Heat treatment
  • Curing tube CDCC, DN 250-10 zones
  • Siccon 6000 Catenary Control System
  • THS Tube heating system
  • N2P Nitrogen Pressure Control System
  • NCS Nitrogen Circulation System
  • Cooling Tube DN 200-120 m
  • OWCS Open Water Cooling System
  • ES 200 DS Douple End seal
  • KLH-HD Cable Twister
  • By Product Separator
  • BCA 42 Caterpillar
  • TPU 3600 Turn Pulley
  • SL 150 Dancer
  • BLMD 2000 Belt length measuring system
  • BCA 18 Caterpillar
  • FTU 30.16-40 floor pay-off
  • FTU 30.16-40 floor pay-off
  • Autocure 4.1 S7 Line Control

Specifications

Voltage range 66 – 500 kV
Conductor cross section Cu mm2 240 –2500
Conductor cross section Al mm2 240 –2500
Conductor type Round, solid, stranded
Insulation layer thicknesses  
Conductor screen (mm) 0.4 – 2.0 mm
Insulation (mm) up to 32 mm
Insulation screen (mm) 0.4 – 2.0 mm
Max. cable weight (kg/m) 33
Max. Cable diameter (mm) 140
Lenght of typical line (m) 220
Extruder platform height (m) 23.5
Constructive line speed (m/min) 25

Value packages

Production Capacity

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

High Output Value Package for HV/EHV CCV Lines

High and extra high voltage cables have important insulation thicknesses, and considerable insulation weight is supported by a small conductor. If the viscosity of the material close to the conductor decreases, as is the case when the temperature increases rapidly, significant drooping occurs and the insulation will be off-centered. In addition to eliminating the drooping effect, our patented method increases heating and cross-linking capacity, and thus line speeds, in catenary continuous vulcanizing lines for medium, high and extra high voltage cable production.

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors and high voltage (HV) Milliken conductors up to 3000 mm².

Production Cost

Quick Conductor Splicing Value Package for HV/EHV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors and high voltage (HV) Milliken conductors up to 3000 mm².

Product Quality

Clean Run Value Package

While your compound suppliers provide clean XLPE insulation compounds, with our clean-run value package these compounds are kept clean. In fact, they are made even cleaner through the material conveying from the package to the extruder.

Long Run Value Package

By utilizing reliable line components and avoiding pre-cross-linking in the extrusion process, you can achieve long cable production lengths. It is particularly true in subsea cable production, where minimizing the number of joints is essential.

Round Value Package Basic

The cooling circulation of nitrogen shrinks the outer surface of the insulation, thereby forcing the insulated core into its round shape. This process enables a catenary line with moderate rotation to produce cables with thick walls.

Meet us at Wire & Cable Arabia 2017 in Dubai, UAE on 17 - 19 December, 2017!

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