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Cable Physical Foam Insulation Production Line
Cable Physical Foam Insulation Production Line

Cable Physical Foam Insulation Production Line

The Physical Foam Insulation Production Line is a high-end manufacturing system tailor-made for LAN cable production. It is suitable for the physical foaming insulation processing of various high-performance communication cables and coaxial cable cores. The line is particularly well-suited for producing LAN cable cores such as IEEE 1394, CAT7, and CAT8, supporting both physical foam and solid extrusion applications. Utilizing advanced physical foaming technology, the system injects nitrogen evenly into the insulation material to form a lightweight, low-dielectric-constant foam layer, significantly enhancing the cable’s signal transmission performance and data speed.
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Cable Drawing Insulation Tandem Line

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  • Parameter
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  • 1、Line speed：800-1200m/min
    2、Foaming degree：max65%
    3、Insulation outer diameter: max 3.0 mm
    4、Temperature control：±1°C

About Us
Zhangjiagang Dachen Machinery Manufacturing Co., Ltd.
Zhangjiagang Dachen Machinery Manufacturing Co., Ltd.
Zhangjiagang Dachen Machinery Manufacturing Co., Ltd. established in 1997, we are Custom Cable Physical Foam Insulation Production Line Manufacturers and Cable Physical Foam Insulation Production Line Company, specializes in the research, development, and manufacturing of cable production equipment. Located in Jinfeng Town, Zhangjiagang—recognized as a national-level sanitary city—the company operates a modern 10,000 m² production facility, with an annual output value exceeding 50 million yuan.
As a national high-tech enterprise and a "Specialized, Refined, Characteristic, and Innovative" SME in Jiangsu Province, Dachen employs over 60 professionals, including a strong team of senior engineers who account for more than 20% of the staff. The company is ISO 9001:2008 certified, with its production capacity and technical expertise ranking among the best in the industry.
Dachen Machinery offers complete cable production equipment solutions—including LAN cable lines, industrial cable systems, plastic processing machinery, and customized non-standard equipment. With in-house control over the entire development process—from mechanical structure to electrical systems—the company ensures fast delivery and tailored service. Dachen is trusted by customers for its outstanding cost performance, fine craftsmanship, and dedicated after-sales support.
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Industry knowledge

What types of cables is the Cable Physical Foam Insulation Production Line suitable for?

Applicable Cable Types

1. High-Speed ​​Local Area Network (LAN) Cables

Compatible with high-speed transmission standards such as IEEE 1394, Cat7, and Cat8, meeting gigabit and even 10-gigabit data rate requirements.

Utilizing physical foam insulation significantly reduces the dielectric constant and improves signal integrity.

2. Coaxial Cable Core

Suitable for coaxial cables used in RF, broadband, and video transmissions. The foam layer provides lightweight shielding without affecting impedance matching.

3. High-Performance Communication Fiber Optic Preforms (Preforms)

Adding lightweight foam to the outer layer of the fiber optic preform improves bending resistance and reduces overall weight.

4. Industrial-Grade High-Temperature/Oil-Resistant Cables

By adjusting the foam formulation, high-temperature resistance, oil resistance, or flame-retardant properties can be achieved to meet the demands of harsh operating conditions.

What are the key processes in the Cable Physical Foam Insulation Production Line?

Key Process Overview

1. Preheating and Batching

Precisely control the temperature of insulating materials (such as polyethylene and PVC) to ensure uniform foaming.

2. Nitrogen Injection and Physical Foaming

Utilizing advanced nitrogen uniform injection technology, micropores are formed within the material under high pressure, achieving a foaming degree of up to 65%.

3. Extrusion Molding

The foamed material and conductor are simultaneously formed using a high-precision extruder, with an outer diameter of up to 3mm, meeting fine wire specifications.

4. Precise Temperature Control

A ±1°C temperature control system ensures the stability of foam layer thickness and dielectric constant.

5. Online Monitoring and Quality Traceability

Real-time monitoring of line speed (800-1200 m/min) and foaming degree, combined with the ISO9001:2008 quality system, enables full-process traceability.

What are the advantages of the Cable Physical Foam Insulation Production Line in terms of material utilization, weight, and cost compared to traditional solid extrusion?

Dimension Traditional Solid‑Core Extrusion Physical Foam Insulation Production Line
Material Utilization Insulation material is completely solid, resulting in a relatively high waste rate. Nitrogen injection creates internal micro‑pores, improving material utilization by about 30%–40%.
Product Weight Weight increases linearly with insulation thickness. The foam layer has low density, reducing overall weight by 20%–35%.
Production Cost High raw‑material cost and large energy consumption. Foam formation reduces raw‑material usage and provides more stable temperature control, cutting energy consumption by roughly 15%.
Signal Performance Dielectric constant is relatively fixed, limiting high‑speed transmission. The foam layer has a lower dielectric constant, resulting in less signal attenuation and supporting higher frequencies.

Frequently Asked Questions (FAQ)
Q1:What are the company's competitive advantages in the industry?

A: The company possesses a complete closed loop of R&D, manufacturing, sales, and service, ensuring fast project delivery, high product cost-effectiveness, and earning the trust of domestic and international customers.

Q2:In which areas are the company's technological advantages reflected?
A: From mechanical structure to electrical system, the entire process is internally controlled, ensuring fast delivery, customized services, and comprehensive after-sales support.

Q3:What are some typical product lines?
A: Machine backtwist, single strand twisting machine, drawing annealing machine, drawing insulation tandem wire, double twisting machine, cable sheath extrusion line, braiding and winding machine, rewinding machine, combined twisting machine, etc.

Q4:What is Dacheng Machinery's corporate positioning?

A: A national high-tech enterprise and a Jiangsu Province "Specialized, Refined, and Innovative" SME.