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High Voltage Vertical 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 quality insulation and vulcanizing of high and extra high voltage cable. Thanks to accurate layer tolerances and precise control of material consumption, you also reduce your amount of scrap.

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.

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

EPL 51Extend

Gain flexibility when producing quality high and extra high voltage XLPE cables

Are you looking for a flexible insulation and vulcanizing process which is easy to operate and performs reliably?

For your production of high and extra high voltage cables, our EPL 51 Extend offers you

  • High-quality results
  • Fast line speeds
  • Easy cable system installation and controlled material costs

What you get

Cable manufactured to meet specific requirements and international standards

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

Performance

Theoretical yearly capacity

200 km, 1000 mm2 Cu 220 kV

Typical line composition

  • FBO 30 Floor pay-off
  • FBO 30 Floor pay-off
  • KS160 Vertical cable clamp
  • SL 150 Dancer
  • MHE DB 2000LV/5+6/80m Accumulator
  • HSC 3500 V High Stability Capstan
  • EFD 50 Conductor Preheater
  • NXW 60-20D Water cooled extruder
  • NXW 175-24D Water cooled extruder
  • NXW 80-20D 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
  • Curing tube CDCC, DN 250-7 zones
  • THS Tube heating system
  • N2P Nitrogen Pressure Control System
  • NCS Nitrogen Circulation System
  • Vertical Cooling Tube DN 200-48 m
  • PTP 3600L Pressurized Turn Pulley
  • Vertical Cooling Tube DN 200-36 m
  • OWCS Open Water Cooling System
  • ES 200 SS End seal
  • BCA 21 Caterpillar
  • SL 150 Dancer
  • BLMD 2000 Belt length measuring system
  • BCA 15 Caterpillar
  • FTU 30 Floor pay-off
  • FTU 30 Floor pay-off
  • Autocure 4.1 S7 Line Control
  • Optional component

    By Product Separator

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, miiliken
Insulation layer thicknesses  
Conductor screen (mm) 0.4 – 2.0 mm
Insulation (mm) 3.4 – 35
Insulation screen (mm) 0.4 – 2.0 mm
Max. cable weight (kg/m) 35
Max. Cable diameter (mm) 140
Height of the tower (m) 100
Constructive line speed (m/min) 10

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.

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.

Round Value Package Premium

Optimal roundness is essential for efficient use of insulation material on a CV line. Cutting down material overuse is one of the biggest contributors to production productivity in pre-molded and pre-fabricated joints and terminations as well.

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.

Round Value Package Premium

Optimal roundness is essential for efficient use of insulation material on a CV line. Cutting down material overuse is one of the biggest contributors to production productivity in pre-molded and pre-fabricated joints and terminations as well.

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

EPL 51Explore

Produce quality high and extra high voltage XLPE cables with high speed

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

Our EPL 51 Explore line is designed for reliable, high-quality production of high and extra high voltage cables, and offers

  • First-rate production
  • High-speed production
  • Minimized material costs and easy installation

What you get

Cable manufactured to meet all relevant requirements and meets international standards

  • Top-quality high and extra high voltage cable
  • Exceptional high and extra high voltage cable production
  • Minimum tower height

Performance

Theoretical yearly capacity

250 km, 1000 mm2 Cu 220 kV

Typical line composition

  • FBO 30 Floor pay-off
  • FBO 30 Floor pay-off
  • KS160 Vertical cable clamp
  • SL 150 Dancer
  • MHE DB 2000LV/5+6/80m Accumulator
  • HSC 3500 V High Stability Capstan
  • EFD 50 Conductor Preheater
  • NXW 60-20D Water cooled extruder
  • NXW 200-24D Water cooled extruder
  • NXW 80-20D Water cooled extruder
  • NXW Cooling unit for extruder group
  • THX 70/165HV 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
  • Postheating equipment
  • Curing tube CDCC, DN 250-4 zones
  • THS Tube heating system
  • Vertical neutral tube DN250-5 m
  • N2P Nitrogen Pressure Control System
  • NCS Nitrogen Circulation System
  • Vertical Cooling Tube DN 260-60 m
  • PTP 3600U Pressurized Turn Pulley
  • Vertical Cooling Tube DN 250-42 m
  • OWCS Open Water Cooling System
  • ES 200 SS End seal
  • BCA 42 Caterpillar vertical
  • SL 150 Dancer
  • BLMD 2000 Belt length measuring system
  • BCA 15 Caterpillar
  • FTU 30 Floor pay-off
  • FTU 30 Floor pay-off
  • Autocure 4.1 S7 Line Control
  • Optional component

    By Product Separator

Specifications

Voltage range 66 – 500 kV
Conductor cross section Cu mm2 240 –3000
Conductor cross section Al mm2 240 –3000
Conductor type Round, solid, stranded, miiliken
Insulation layer thicknesses  
Conductor screen (mm) 0.4 – 2.0 mm
Insulation (mm) 3.4 – 35
Insulation screen (mm) 0.4 – 2.0 mm
Max. cable weight (kg/m) 40
Max. Cable diameter (mm) 150
Height of the tower (m) 100
Constructive line speed (m/min) 10

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.

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.

Round Value Package Premium

Optimal roundness is essential for efficient use of insulation material on a CV line. Cutting down material overuse is one of the biggest contributors to production productivity in pre-molded and pre-fabricated joints and terminations as well.

Production Cost

Round Value Package Standard

Roundness is a sum of many factors during the extrusion and cross-linking processes. Correct extrusion and cross-linking conditions can be achieved and controlled with correct equipment selection.

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.

Round Value Package Standard

Roundness is a sum of many factors during the extrusion and cross-linking processes. Correct extrusion and cross-linking conditions can be achieved and controlled with correct equipment selection.

Round Value Package Premium

Optimal roundness is essential for efficient use of insulation material on a CV line. Cutting down material overuse is one of the biggest contributors to production productivity in pre-molded and pre-fabricated joints and terminations as well.

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

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