Inside Farwalk Cable’s 6–35 kV Three-Layer Co-Extrusion Dry Crosslinking Line

• 2026-08-22 
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Inside Farwalk Cable’s 6–35 kV Three-Layer Co-Extrusion Dry Crosslinking Line

Inside Farwalk Cable’s factory, the 35 kV cable production line is identified on site more precisely as a “6–35 kV three-layer co-extrusion dry crosslinking production line.” The equipment extends across a long production route, linking the extrusion area with process monitoring, online measurement or inspection equipment, and the final take-up area.

This is part of the factory environment used for medium-voltage cable manufacturing. Seen as a complete route rather than a group of separate machines, the line shows how several important stages are connected: three layers are applied around the conductor, the extruded insulation system passes through the crosslinking stage, operating conditions are monitored, and the processed cable core is collected on a reel.

A Production Line Built for Medium-Voltage Cable Manufacturing

Medium-voltage cable construction requires more than placing a single layer of insulation over a conductor. A typical XLPE-insulated medium-voltage cable core includes an inner semiconductive conductor screen, the main insulation layer, and an outer semiconductive insulation screen. These layers form an electrical insulation system around the conductor before the cable moves to the later stages required by its final design.

Farwalk Cable’s 6–35 kV cable production line brings the extrusion and dry crosslinking stages into one connected manufacturing route. Its role is to produce the screened and insulated cable core used in applicable medium-voltage cable constructions. The exact conductor, layer dimensions, materials, and later cable components are determined by the approved product specification for each order.

What Three-Layer Co-Extrusion Means

In this manufacturing context, three-layer co-extrusion means that the conductor screen, XLPE insulation, and insulation screen are formed together during one continuous extrusion stage.

Each layer has a different function. The inner semiconductive screen creates a controlled interface around the conductor. The insulation provides the main dielectric barrier. The outer semiconductive screen forms a controlled boundary around the insulation and works as part of the cable’s overall screening system in the completed construction.

Applying the three layers through one coordinated extrusion stage allows their formation to be managed as a connected process. The crosshead and associated extrusion equipment bring the material streams together around the moving conductor. From there, the newly extruded cable core continues directly toward the crosslinking section.

The term “three-layer” describes this part of the insulation system; it does not describe the entire finished cable. Depending on the specified cable design, later operations may add other screens, metallic layers, bedding, armor, sheath systems, or additional components.

Understanding the Dry Crosslinking Process

XLPE stands for cross-linked polyethylene. During extrusion, the insulation material is shaped around the conductor. Crosslinking is the following curing stage in which the polymer structure develops a more stable network under controlled processing conditions.

On a dry crosslinking line, this curing stage takes place in an enclosed dry environment rather than using steam as the curing medium. The extruded cable core travels through the extended crosslinking section before moving onward for the next applicable stage of the line. The detailed operating settings depend on the cable design, material system, and approved production instructions.

Because crosslinking is a controlled transformation within the insulation system, extrusion, curing, line operation, and downstream handling are arranged as connected parts of the production route.

Following the Cable Through the 35 kV Cable Production Line

The visible route inside the factory can be understood in five practical sections.

1. Co-extrusion equipment and interface area

As the conductor reaches the co-extrusion area, the three functional layers are applied through the connected extrusion equipment. This is the point where the conductor screen, insulation, and insulation screen come together around the conductor. The setup includes the equipment and interfaces needed to coordinate this stage of production.

2. The extended line body

After extrusion, the cable core continues through the long enclosed section associated with the crosslinking process. The physical length of the route is immediately noticeable in the factory view. It reflects the continuous path between applying the insulation system and completing the curing stage.

3. Operation and monitoring area

Control interfaces allow operators to observe the production line and manage the process according to the applicable production instructions. The settings used are specific to the cable design and the production plan.

4. Online measurement or inspection equipment

Equipment positioned along the route provides online measurement or checking functions during production. This allows relevant process information to be reviewed while the cable core moves through the line. The data available depends on the equipment function and the production setup.

5. Take-up and reel area

At the end of the visible route, the processed cable core reaches the take-up area and is wound onto a reel. Take-up supports orderly collection and handling after the extrusion and crosslinking stages. The reel can then move to the next manufacturing operation required by the cable construction.

Together, these sections show a continuous production logic: apply the insulation system, carry it through crosslinking, monitor the process, perform the applicable online checks, and collect the processed cable core for downstream work.

From Production Capability to Project Requirements

A 6–35 kV dry crosslinking line establishes an important manufacturing foundation, but every medium-voltage cable project still begins with a defined technical requirement. Voltage rating, conductor material and size, insulation and sheath construction, applicable standard, required length, reel or packaging arrangement, and documentation must be reviewed for the specific inquiry.

This technical confirmation connects the available factory process with the cable the project actually requires. It also gives both sides a clear basis for discussing construction, production scope, inspection documents, and delivery arrangements before an order is finalized.

Talk to Farwalk Cable About Your Medium-Voltage Cable Project

If you are sourcing medium-voltage cable for a power project, distribution business, industrial application, or another use, send Farwalk Cable your technical requirements for review.

Please include the voltage rating, conductor details, cable construction, applicable standard, required quantity and lengths, packaging preference, destination, and document requirements where available. Our team can then discuss the applicable cable solution and confirm the next technical and commercial steps with you.