100+60 Extruder Insulation & Sheathing Line

The machine is used for the production of PVC coated fence wire up to max. 8mm. When using 3–3.5mm wire as semi-finished product with plastic coating, this high-capacity machine can achieve up to 10 tons per day, provided there are no stoppages.

 

VX60 HIGH-CAPACITY PVC COATED FENCE WIRE EXTRUSION LINE

APPLICATION

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The machine is designed for the production of PVC coated fence wire up to max. 8mm. When using 3–3.5mm wire as semi-finished product with plastic coating, and if the line operates without interruption, it is capable of reaching a high capacity of 10 tons per day.

MAIN LINE FEATURES

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The line allows fast PVC coating of fence wire up to 8mm in diameter. Single-layer extrusion application is possible. A self-centering 6mm head is used, with a bypass unit mounted on the head.

This production line consists of a 60mm extruder, automatic fine adjustment head, and other equipment depending on material type, production speed, and wire cross-section. Extruders are designed with 8550 material screws and barrels suitable for PVC.

Wire diameter is continuously controlled by PLC independent of line speed. The extruder speed is automatically adjusted according to the set diameter and line speed, ensuring consistent diameter throughout production.

Basket winder ensures continuous production with proper winding at high speeds.

Cooling trough ensures effective cooling of PVC wire, enabling high-quality production and preventing sticking during winding to the basket.

With a capstan suitable for speeds up to 300m/min, high-speed production is possible. Capstan also assists in diameter control to avoid sudden variations in PVC wire diameter.

Latest PLC and drives, with a 15-inch wide color touchscreen, provide user-friendly operation. Operator can view all parameters, only needs to set line speed and wire diameter, and the machine will operate all equipment in synchronization. This reduces the need for the operator to constantly monitor the line.

During production, the operator can handle other tasks such as wire feeding, basket preparation, and material loading, resulting in more efficient and higher-quality production.

MACHINE EQUIPMENT TECHNICAL SPECIFICATIONS

 

Wire Pay-off (1 Unit)

• Suitable for loading two baskets, allowing production to continue with welding the backup basket without stopping the machine.
• Wire guiding at entry to maintain tension.
• Guide pulleys for wire transfer.
• Horizontal and vertical guiding roller stand before extruder to ensure centered feeding.
• Suitable for operation up to 300m/min line speed.

 

60mm Extruder (1 Unit)

• 300 kg/h PVC capacity.
• Ø60 x 26D EKS barrel manufacturing.
• Ø60 x 26D EKS PVC screw with barrier mixer.
• Barrel material: 1.8550 (DIN 34CrAlNi7 / Nitriding Steel).
• Screw material: 1.8550 (DIN 34CrAlNi7 / Nitriding Steel).
• Nitriding type and duration: Long-term gas nitriding, 72 hours.
• Surface hardness: 950–1100 HV1.
• Nitriding depth: 0.5–0.6mm.
• Threaded screw removal tool.
• Sliding material hopper with visual level indicator.
• Hopper with hinged lid to prevent dust entry.
• Loading platform.
• Max screw speed: 100 rpm.
• 45kW square body Siemens AC motor.
• Motor gearbox coupling.
• 4 heating zones with PID control (heating/cooling).
• 3 head zones (clamp, neck, head) with socket connections.

 

4/6mm Extruder Head (1 Unit)

• 1 pc 4/6 Automatic Head (with 1 PVC heart).
• 1 pc 60mm extruder neck bypass.
• 1 pc extruder screen changer.
• 1 pc extruder clamp.
• Max wire diameter: 8mm.
• Automatic, self-centering head.

Cooling Trough (1 Unit)

• Length: 9m, single layer.
• Inner rollers with stainless shafts.
• Outlet with blower dryer to remove water.
• Divided into 3 parts, connected by flanges.
• Drainage via 2-inch pipe.
• Rubber sealing.
• Inlet connections 3/4″.
• Drain filters with wire mesh.

 

Rotating Capstan (1 Unit)

• Capstan pulley diameter: 900mm.
• Aluminum casting pulley.
• 11kW geared AC motor.
• Max line speed: 300m/min.
• Yılmaz gearbox.
• Cylindrical guide for centering.
• Entry and exit rollers.
• Safety guards and protection system.

 

Basket Winder (1 Unit)

• AC 5.5kW geared winding motor.
• Pulley for wire centering.
• 900mm basket winding with 40° flange.
• Pulley system for winding.
• Storage area for continuous production during basket change. Manual lever allows rewinding stored wire after change.
• Basket trolley with motorized drive and rotary table.
• Safety cage around rotary table.
• Meter sensor on inlet pulley.
• Suitable for operation up to 300m/min.
• Basket change crane and baskets not included.

 

Diameter Gauge (1 Unit)

• High precision diameter gauge.

 

Automation Group (1 Set)​

• PLC: Schneider, Siemens, or Delta.
• Motors: Siemens and Gamak.
• Operator panel: 15-inch touchscreen.
• Drives: Delta, Control Techniques, or Omron.
• Switchgear: Schneider and ABB.
• Automatic diameter control system.
• Extruder, capstan, and winder synchronized with line speed.
• All safety systems activated via software.
• Cables, wiring, and coding (except main supply) included.