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Rubber Cable Catenary Insulation and Sheathing

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

Would you like to reap the benefits of the most advanced and versatile power cable manufacturing system available on the market? SSCV Super Steam is a smart combination of curing processes for cable insulation and sheathing in your manufacturing system. Using our technology, you can choose from a broad range of materials to produce a wide variety of power cables.

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 20Extend

Cutting-edge technology which is applicable in producing a wide array of rubber cable types

Would you like to receive high-quality production and maximum versatility, all from one line?

Our EPL 20 SSCV Super Steam line offers efficient manufacturing of various rubber cable types, with several curing process options

  • High productivity
  • High quality for pressure sensitive cables
  • Technology applicable across a wide range of power cables

What you get

Top-of-the-line efficiency and versatility for your power cable production

  • Large curing capacity of the Super Steam process and the adjustable cooling length creates maximum productivity for all cable types
  • Eliminating high pressures helps preserve the sensitive construction of cables
  • Highly versatile steam curing process is applicable in a wide range of rubber cable products

Performance

Typical capacity increase compared to traditional steam line

35 %

Typical line composition

  • AVR 15 Pay-off
  • AVR 15 Pay-off
  • SL 120 Dancer
  • Welding machine
  • KS 140 Cable clamp
  • MHE DB 2000LV/5+6/120m Accumulator
  • BCA 30 Caterpillar
  • NMR 60-16D Water cooled extruder
  • NMR 150-16D Water cooled extruder
  • NMR 100-16D Water cooled extruder
  • THR 40/70 Crosshead for single/dual/triple-layer insulating
  • NHW 100 Crosshead for layer sheathing
  • CCV Tube
  • SB 150 Splice box
  • X-RAY 8000 Diameter
  • Steam pressure control system
  • Curing tube Super Steam, DN 200 - 5 zones
  • Super Steam heating system
  • Tube air cooling jackets
  • SICCON 600 Catenary control system
  • Cooling Tube DN 150 - 72 m
  • OWCS Open Water Cooling System, SSCV
  • ES 150 SS End seal
  • BCA 30 Caterpillar
  • TPU 3000 Turn pulley
  • Spark tester
  • SL 120 Dancer
  • BLMD 200 Belt length measuring device
  • BCA 12 Helper caterpillar
  • TUT 15 Take-up
  • TUT 15 Take-up
  • LCU 4.1 S7 Line Control
  • NSS Curing calculation and simulation program
  • Optional components

    Powdering unit
  • Nitrogen Dry Curing process
  • N2P Nitrogen pressure control system
  • Ventilation system
  • By-product separator
  • NCS Nitrogen circulation system
  • N2 upgrade for software and line control
  • DN 250 Curing tube; Curing tube extension
  • Spare parts package

Specifications

Voltage range 2 – 35 kV
Conductor cross section Cu mm2 25 – 800
Conductor cross section Al mm2 70 – 800
Conductor type Round, solid, stranded, bunched
Layer thicknesses  
Conductor screen (mm) 0.3 – 5.0 mm
Insulation (mm) 1.0 – 10
Insulation screen (mm) 0.3 – 5.0 mm
Max. cable weight (kg/m) 21
Max. Cable diameter (mm) Three-layer cables 70; One (two) layer cables: 100 (130)
Lenght of typical line (m) 135
Extruder platform height (m) 11
Line speed, geared (m/min) 50

Value packages

Production Capacity

XLPE Extension Value Package

Maillefer multi-purpose extruders are selected for processing both rubber materials and XLPE. Please note that a nitrogen supply and the necessary equipment are needed for XLPE cable production.

Continuous Type Change Value Package for Rubber Cable Lines

Rubber cables are typically produced in short lengths. It means frequent type changes, long downtime periods and raised costs. Not any more. The well known Maillefer invention for XLPE cables, Continuous Type Change is now available also for rubber cables: several cable sizes can be produced without stopping the line.

Production Cost

N2 Dry Curing Value Package

Our N2 Dry Curing Value Package provides a nitrogen supply and the necessary equipment for the dry curing process. The nitrogen atmosphere is the correct solution for cable materials which are sensitive to oxygen and moisture. Production is independent of steam availability and the costs of steam generation.

Continuous Type Change Value Package for Rubber Cable Lines

Rubber cables are typically produced in short lengths. It means frequent type changes, long downtime periods and raised costs. Not any more. The well known Maillefer invention for XLPE cables, Continuous Type Change is now available also for rubber cables: several cable sizes can be produced without stopping the line.

Product Quality

N2 Dry Curing Value Package

Our N2 Dry Curing Value Package provides a nitrogen supply and the necessary equipment for the dry curing process. The nitrogen atmosphere is the correct solution for cable materials which are sensitive to oxygen and moisture. Production is independent of steam availability and the costs of steam generation.

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

EPL 20Explore

Produce rubber cables with the traditional steam and Super Steam curing processes, or manufacture a variety of low and medium voltage rubber and XLPE cables with the Super Steam Hybrid line and N2 Dry Curing process

Are you searching for an all-in-one line package that includes high productivity and quality, along with maximum versatility?

Our EPL 20 SSCV Hybrid line, which is our most versatile combination of curing processes for rubber and XLPE cables, offers you

  • Unmatched productivity
  • Top-of-the-line-quality in pressure, moisture and oxygen sensitive cables
  • Extreme versatility

What you get

A line for your power cable production that is unbeatable in its efficiency and versatility

  • Large curing capacity of the Super Steam process and the adjustable cooling length creates maximum productivity for all cable types
  • Nitrogen Dry Curing offers moisture- and oxygen-free curing for maximized insulation quality
  • Highly versatile, Hybrid with the Super Steam and Dry Curing processes for medium voltage rubber and XLPE cables, and the Saturated steam and Super Steam processes available for traditional rubber cable manufacturing

Performance

Typical capacity increase compared to traditional steam line

35 %

Typical line composition

  • AVR 15 Pay-off
  • AVR 15 Pay-off
  • SL 120 Dancer
  • Welding machine
  • KS 140 Cable clamp
  • MHE DB 2000LV/5+6/120m Accumulator
  • HSC 3000 Capstan
  • Conductor pre-heater
  • NMR 80-20D Water cooled extruder
  • NMR 150-20D Water cooled extruder
  • NMR 100-20D Water cooled extruder
  • THR 40/70 Crosshead for single/dual/triple-layer insulating
  • DHR 130 for single/dual-layer sheathing
  • CCV Tube
  • SB 150 Splice box
  • X-RAY 8000 Diameter, wall thickness and eccentricity monitoring
  • Steam pressure control system
  • Curing tube Super Steam and Dry Curing, DN 200 - 7 zones
  • Electrical direct heating of the curing tube
  • Tube air cooling jackets
  • SICCON 600 Catenary control system
  • Nitrogen Dry Curing process
  • N2P Nitrogen pressure control system
  • Ventilation system
  • By-product separator
  • NCS Nitrogen circulation system
  • N2 upgrade for software and line control
  • Cooling Tube DN 150 - 84 m
  • OWCS Open Water Cooling System, SSCV
  • ES 150 SS End seal
  • BCA 30 Caterpillar
  • TPU 3000 Turn pulley
  • Spark tester
  • SL 120 Dancer
  • BLMD 200 Belt length measuring device
  • BCA 15 Helper caterpillar
  • TUT 15 Take-up
  • TUT 15 Take-up
  • LCU 4.1 S7 Line Control
  • NSS Curing calculation and simulation program
  • Optional components

    Powdering unit
  • DN 250 Curing tube; curing tube extension
  • Spare parts package

Specifications

Voltage range 1 – 35 kV
Conductor cross section Cu mm2 25 – 800
Conductor cross section Al mm2 70 – 800
Conductor type Round, solid, stranded, bunched
Layer thicknesses  
Conductor screen (mm) 0.3 – 5.0 mm
Insulation (mm) 1.0 – 10
Insulation screen (mm) 0.3 – 5.0 mm
Max. cable weight (kg/m) 21
Max. Cable diameter (mm) Three-layer cables 70; One/two-layer cables: 130
Lenght of typical line (m) 155
Extruder platform height (m) 12-15
Constructive line speed (m/min) 50

Value packages

Production Capacity

Continuous Type Change Value Package for Rubber Cable Lines

Rubber cables are typically produced in short lengths. It means frequent type changes, long downtime periods and raised costs. Not any more. The well known Maillefer invention for XLPE cables, Continuous Type Change is now available also for rubber cables: several cable sizes can be produced without stopping the line.

Production Cost

Continuous Type Change Value Package for Rubber Cable Lines

Rubber cables are typically produced in short lengths. It means frequent type changes, long downtime periods and raised costs. Not any more. The well known Maillefer invention for XLPE cables, Continuous Type Change is now available also for rubber cables: several cable sizes can be produced without stopping the line.

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

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