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Medium 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: +1 972 762 2297

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Reliable insulation and vulcanizing technology for continuous and high-speed medium voltage cable production. You also have complete control over material usage.

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 30Enter

Produce quality medium voltage XLPE cables with reduced budget

Are you searching for an easy start to your medium voltage production?

Our EPL 30 Enter cable production line is optimized for the needs of a new player by offering

  • Manufacturing start with minimal investment
  • User-friendliness and reduced maintenance minimize operation costs
  • Reduce material costs by limiting waste

What you get

Immediate production from the very first day

  • Reliable, worry-free medium voltage cable production
  • Maintenance-free line design and built-in operator support
  • Leading technology proven worldwide

Performance

Theoretical yearly capacity

2500 km, 240 mm2 Al 10 kV

Enjoy the benefits

The Maillefer catenary continuous vulcanizing line is designed for continuous insulation of XLPE insulated cable cores. The conductor is insulated by proven XLPE extruders and triple crossheads. The combination of the advanced Autocure line control system, triple crosshead and X-ray dimensional measurement provides the possibility to minimize start-up scrap and material over-consumption during your cable production run.

Typical line composition

  • FPO 20LV Floor pay-off
  • MHE DB 1600LV/4+5/120m Accumulator
  • TPU 1200 Turn Pulley
  • BCA 15 Caterpillar
  • Preheater
  • MXI 80-20D Air cooled extruder
  • MXI 150-24D Air cooled extruder
  • MXI 80-20D Air cooled extruder
  • THX 35/75MV Triple crosshead
  • X-RAY 8000 Diameter
  • SB 60, CCV, Splice box
  • Curing tube CDCC, DN 150-7 zones
  • Pressure release system
  • Cooling Tube DN 100-72 m
  • LOWCS Light Open Water Cooling System
  • ES 60 SS Manual End seal
  • BCA 18 Caterpillar
  • TPU 2000 Turn Pulley
  • FTU 20LV Floor take-up
  • LCU4.1 S7 Line Control
  • NCC curing calculation and simulation

Specifications

Voltage range 10 – 35 kV
Conductor cross section Cu mm2 25 – 630
Conductor cross section Al mm2 25 – 800
Conductor type Round, solid, stranded
Insulation layer thicknesses  
Conductor screen (mm) 0.3 – 2.0 mm
Insulation (mm) 3.4 – 10.5
Insulation screen (mm) 0.3 – 2.0 mm
Max. cable weight (kg/m) 7.0
Max. Cable diameter (mm) 60
Length of typical line (m) 150
Extruder platform height (m) 10
Constructive line speed (m/min) 25

Value packages

Production Capacity

Quick Conductor Splicing Value Package for MV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors up to 800 mm².

Production Cost

Quick Conductor Splicing Value Package for MV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors up to 800 mm².

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

EPL 30Extend

Manufacture quality medium voltage XLPE cables with minimum material costs

Are you interested in a reliable insulation and vulcanizing process?

Our EPL30 Extend cable production line is designed for reliable, high-quality production of medium voltage cables and offers

  • High-quality results
  • Fast line production
  • Reduce material costs by limiting waste

What you get

Cable that fulfills all of the end user's requirements

  • High-performance, worry-free medium voltage cable production
  • Maintenance-free line design and built-in operator support
  • Leading technology proven worldwide

Performance

Theoretical yearly capacity

5000 km, 240 mm2 Al 10 kV

Customer case

In a proven case, a customer was able to use the High Stability Capstan to achieve less than 0.2% line speed variation and less than 0.1% longitudinal diameter variation.

Typical line composition

  • AVR 15.10-30 Portal pay-off
  • AVR 15.10-30 L2 Portal pay-off
  • KS160 Vertical cable clamp
  • SL 120 Dancer
  • MHE DB 1600LV/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 50/90 Triple crosshead
  • IWT 300 Integrated Water Tempering unit
  • X-RAY 8000 Diameter, Wall thickness and Eccentricity measuring system
  • Material handling system
  • SB 150 Splice box
  • Curing tube CDCC, DN 200-8 zones
  • Siccon 6000 Catenary Control System
  • THS Tube heating system
  • N2P Nitrogen Pressure Control System
  • NCS Nitrogen Circulation System
  • Cooling Tube DN 150-90 m
  • OWCS Open Water Cooling System
  • ES 150 SS End seal
  • KLH-HD Cable Twister
  • BCA 21 Caterpillar
  • TPU 2000 Turn Pulley
  • SL 120 Dancer
  • BLMD 2000 Belt length measuring system
  • BCA 12 Caterpillar
  • TUT 15.10-30 L2 Portal take up
  • TUT 15.10-30 Portal take up
  • Autocure 4.1 S7 Line Control

Specifications

Voltage range 10 – 35 kV
Conductor cross section Cu mm2 25 – 800
Conductor cross section Al mm2 25 – 800
Conductor type Round, solid, stranded
Insulation layer thicknesses  
Conductor screen (mm) 0.4 – 2.0 mm
Insulation (mm) 3.4 – 12
Insulation screen (mm) 0.4 – 2.0 mm
Max. cable weight (kg/m) 10
Max. Cable diameter (mm) 70
Lenght of typical line (m) 180
Extruder platform height (m) 12
Constructive line speed (m/min) 50

Value packages

Production Capacity

Continuous Type Change Value Package for MV CCV Lines

It is possible to produce several medium voltage cores in the same run without stopping the continuous vulcanization line. This significantly reduces overall downtime, especially if the production contains frequent type changes. Continuous Type Change Value Package, which you can upgrade to without heavy investment, is an effective means to improve productivity.

High Output Value Package for MV CCV Lines

Typical preheaters ineffectively heat conductors, causing the inner semicon material to penetrate the outermost wires. In a worst case scenario, the conductors can then no longer pass through the wire guide of the crosshead. Our Dual Preheating System uses two coils to effectively heat the entire conductor.

Quick Conductor Splicing Value Package for MV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors up to 800 mm².

Production Cost

Quick Conductor Splicing Value Package for MV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors up to 800 mm².

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

EPL 30Explore

Produce high-quality medium voltage XLPE cables with minimum operation costs

Would you like an insulation and vulcanizing process that keeps your cost per production meter under control?

Our EPL 30 Explore line is designed for production at high speeds, and offers

  • High performance with low operational costs per produced meter of cable core
  • Top-quality cable that meets all of the end user's requirements
  • Reduce material costs by limiting waste

What you get

Fastest line speeds available on the market

  • High-quality production with minimal material costs
  • Maintenance-free line design and built-in operator support
  • Leading technology proven worldwide

Performance

Theoretical yearly capacity

7000 km, 240 mm2 Al 10 kV

Customer case

With our Dual preheating system, a customer was able to increase line speeds by 25%. 

Typical line composition

  • AVR 15.10-30 Portal pay-off
  • AVR 15.10-30 L2 Portal pay-off
  • KS160 Vertical cable clamp
  • SL 120 Dancer
  • MHE DB 1600LV/5+6/120m Accumulator
  • EFD 50 Conductor Preheater before capstan
  • HSC 2000 C High Stability Capstan
  • EFD 50 Conductor Preheater before crosshead
  • NXW 100-20D Water cooled extruder
  • NXW 200-24D Water cooled extruder
  • NXW 120-20D Water cooled extruder
  • NXW Cooling unit for extruder group
  • THX 50/90 Triple crosshead
  • IWT 300 Integrated Water Tempering unit
  • X-RAY 8000 Diameter, Wall thickness and Eccentricity measuring system
  • Material handling system
  • SB 150 Splice box
  • Curing tube CDCC, DN 200-10 zones
  • Siccon 6000 Catenary Control System
  • THS Tube heating system
  • N2P Nitrogen Pressure Control System
  • NCS Nitrogen Circulation System
  • Cooling Tube DN 150-120 m
  • OWCS Open Water Cooling System
  • ES 150 SS End seal
  • KLH-HD Cable Twister
  • By Product Separator
  • BCA 21 Caterpillar
  • TPU 2000 Turn Pulley
  • SL 120 Dancer
  • BLMD 2000 Belt length measuring system
  • BCA 12 Caterpillar
  • TUT 15.10-30 L2 Portal take up
  • TUT 15.10-30 Portal take up
  • Autocure 4.1 S7 Line Control
  • Optional components

    CTC Continuous type Change
  • PDI Isolator
  • Ultratemp Non contact melt temperature measurement
  • Cinegran Optical flow meter Cinegran
  • Nitrogen generator
  • Water cleaning unit
  • Diameter gauge
  • Conductor Welding
  • Internal communication system
  • CHT Crosshead handling table

Specifications

Voltage range 10 – 35 kV
Conductor cross section Cu mm2 25 – 800
Conductor cross section Al mm2 25 – 800
Conductor type Round, solid, stranded
Insulation layer thicknesses  
Conductor screen (mm) 0.4 – 2.0 mm
Insulation (mm) 3.4 – 12
Insulation screen (mm) 0.4 – 2.0 mm
Max. cable weight (kg/m) 10
Max. Cable diameter (mm) 70
Lenght of typical line (m) 220
Extruder platform height (m) 16
Constructive line speed (m/min) 100

Value packages

Production Capacity

Continuous Type Change Value Package for MV CCV Lines

It is possible to produce several medium voltage cores in the same run without stopping the continuous vulcanization line. This significantly reduces overall downtime, especially if the production contains frequent type changes. Continuous Type Change Value Package, which you can upgrade to without heavy investment, is an effective means to improve productivity.

High Output Value Package for MV CCV Lines

Typical preheaters ineffectively heat conductors, causing the inner semicon material to penetrate the outermost wires. In a worst case scenario, the conductors can then no longer pass through the wire guide of the crosshead. Our Dual Preheating System uses two coils to effectively heat the entire conductor.

Quick Conductor Splicing Value Package for MV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors up to 800 mm².

Production Cost

Quick Conductor Splicing Value Package for MV CV Lines

Our Quick Conductor Splicing Value Package allows quick conductor splicing for compact round stranded medium voltage (MV) conductors up to 800 mm².

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