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Compounding Plants for the Cable Industry

A Company of the
TROESTER Group

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Continuous Cable
Compound Processing

The cable industry requires more and more consistency,


reproducibility and consistent product cleanliness towards
the use of continuous compounding systems.

Since founding, X-Compound manufactured and continuously Due to a high expertise X-Compound advanced to a market leader.
developed suitable compounding plants for the processing of X-Compound supplied complete compounding plants to important
any kind of wire & cable materials. cable manufacturers.

The major demands are The design and versatility of the process relevant parts allows a
smooth and intensive kneading and mixing as well as the accurate
> Accurate dosing control of the required process temperature profiles.
> Perfect dispersion and homogeneity
> Energy-saving process
> Versatility

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Halogen-free Flame Retardant Compounds
(HFFR)

Flame retardant cable compounds are designed to have


reduced flammability in order to protect the operation
of the cable.

HFFR halogen-free cable compounds are the optimum solution Advantages of the X-Compound Kneader Technology
for a broad range of cables meeting IEC fire test standards. Used
for both insulation and jacketing, HFFR halogen-free cable com- > Work in of high filler content up to 80% by a
pounds maximize value by providing superior process efficiency. split feed system
Its innovative low-density formulation increases yield, lends to > Special degassing system related to the kneader and
minimizing waste and processes under lower extruder motor load. the product inlet zones to allow optimal filler-intake
> Injection of coupling agent liquids into the melt
Applications > Accurate process temperature control to prevent
degradation of the fillers. (e.g. ATH < 185°C)
> Low price cables for buildings, ultrathin wires for > High flexibility for the processing of a large variety of
automobile up to military/aerospace cables compounds with a unique screw profile

HFFR Line a s p ir a tio n s y s te m

A D D IT IV E S
A T H A T H
E V A E V A P E
F IL L E R S P O L Y M E R
v a c u u m p u m p

s c re e n c h a n g e r

v a c u u m
6 .3
6 .5
d is c h a r g e
6 .4

X -C O M P O U N D K N E A D E R
C K C H D 1 5 0 -2 0 0 (1 8 L /D )

L IQ U ID S
c u s to m e rs
B ig b a g / O c ta b in
w e ig h in g

O il O il O il O il O il w a te r w a te r u n d e r w a te r
p e lle t iz e r

H e a tin g c o o lin g u n its

HFFR 3

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PVC Cable
Compounds

A significant role in the cable industry is the use of PVC PVC cable compounds are divided into the categories
insulation material. The market share is worldwide more than
70% of the cable sector. > Insulation
> Sheathing
PVC cables are mainly used in the low voltage segment > Bedding
in applications as:
For PVC compounding combined with the pelletizing system
> Telecommunications X-Compound use the established cascade kneader design.
> Installations
> Machinery and equipment homogeneous gelification by controlling of
Requirements, such as homogeneou
> Automotive industry H O T dispersive distribution of the
product temperature and/as well as d
> Household T U R B O - superbly in the X-Compound
fillers and additives will implement su
M IX E R
> Communication- and operation window can be covered
Kneader. Furthermore a large operat
control cables which is decisive for frequently
with a single screw configuration, wh
> Semi conductive PVC cables MA C
formulation changeovers.

process are easily handling, fast


Advantages of this two stage proces
self cleaning behavior.
recipe changeovers and excellent se

M
C O O L IN G A C X-Compound offers
M IX E R

> Turn key projects


> Hybrid (PVC/HFFR) compounde
compounder
PVC Line

IN T E R M E D IA T E
S IL O 1 ,5 m ³
D R Y B L E N D

X -C O M P O U N D K N E A D E R v a c u u m

C K IC D 1 5 0 -2 0 0
s c re e n c h a n g e r

v a c u u m p u m p

w a te r w a te r O il O il O il
p e lle t tr a n s p o r t,
c o o lin g , d r y e r M

H e a tin g c o o lin g u n its

F IN A L P R O D U C T

4 PVC
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Cross-linkable PE Compounds
(XLPE)

Peroxide cross-linkable XLPE (PEX-A) The X-Compound inline process is designed as follows:

The peroxide cross-linkable XLPE compounds are applicable


for medium and high voltage cables. > In the first step the polymer with the additives (except
peroxide) have to be mixed to a homogeneous well
The peroxide cross-linkable XLPE compounds have to fulfill dispersed compound and fed through a high performance
exceptional demands in cleanliness and quality to reach high filter system to assure the highest possible purity degree.
physical requirements on dielectric strength and lifetime.
> The second step contains the inline transport of the pure
polymer pellet into a specially designed mixing tumbling
machine which incorporates the peroxide mist over a
controlled time period.

The process as described allows the production of


super clean material on high throughput rates.

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Cross-linkable PE Compounds
(XLPE)

Silane cross-linkable XLPE (PEX-B)

Silane grafted (Sioplas) cross-linkable Polyethylene (XLPE) The X-Compound kneader technology is perfectly capable to
compounds are suitable for the use in the manufacture of low process any kind of grafted polymer compounds. The crosslinking
voltage as well as medium voltage cables up to 33 kV. process is worldwide established.

Independent steps: The process to produce grafted polymers can be implemented


on a relatively short process length maintaining optimal mixing
1. Preparation of the grafted polymer (dispersion) and grafting results. The same proven technique is
2. Cable extrusion with addition of catalyst masterbatch (~5%). also suitable to process flame retardant compounds.

Both compounds are produced on the X-Compound Kneader. Advantages of the X-Compound Kneader
Due to economic reasons it is recommendable to buy the catalyst
masterbatch from specialised manufacturing companies. > Direct injection of silane into the polymer melt
> Minimum material deposits inside the process area due to
the self cleaning kneader principle
> Perfect mixing behavior allows reduction of silane quantity
A P O L Y M E R > Reproducible grafting reaction

Silane
A D D IT IV E S
XLPE Line 0 ,4 m ³

LV, MV
m e ta l
d e te c to r
A A

A v a c u u m u n d e r w a te r
m e lt p e lle tiz e r
p u m p

X -C O M P O U N D K N E A D E R s c re e n c h a n g e r
C K M P D 1 5 0 -1 1 0

S IL A N E
IN J E C T IO N
H e a tin g c o o lin g u n its v a c u u m p u m p

6 XLPE Insulation
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Semi Conductive Compounds

One of the key components in power cables are


semi conductive compounds.

The main task on the manufacturing of semi conductive com- Advantages of the X-Compound Kneader Technology
pounds is the perfect incorporation of high structure carbon
black into the polymer matrix. In order to keep the required > Uniform mixing and distribution of high structure carbon
conductivity it is of importance to prevent any damage of the black
carbon black structure. > Split feeding of conductive carbon black which permits
high level of filler loading and minimize the critical formation
The X-Compound Kneader is well adapted to requirements of agglomerates
as homogenizing and dispersing (break up of agglomerates), > Precise temperature control to prevent degradation of the
wetting and distributing of pigments, additives and fillers into heat sensitive polymers
the polymer matrix. > Smooth mixing process to avoid damage of the filler
chain structure

Semicon a s p ir a tio n s y s te m

Line
A D D IT IV E S
c a r b o n c a r b o n
b l a c k b l a c k E V A E V A P E
F IL L E R S P O L Y M E R

v a c u u m p u m p

v a c u u m
u n d e r w a te r
m e lt
p e lle t iz e r
p u m p

X -C O M P O U N D K N E A D E R s c re e n c h a n g e r
C K M P D 1 5 0 -1 1 0 (2 0 L /D )

L IQ U ID S

c u s to m e rs
B ig b a g / O c ta b in
w e ig h in g

O il O il O il O il O il w a te r w a te r

H e a tin g c o o lin g u n its

XLPE Semicon 7

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Special Applications

Speciality grades, and value added compounds are designated to


make use of the specific features of the X-Compound Kneader
technology.

The controlled shear effect of the X-Compound Kneader is the key


to produce any kind of speciality compounds.

Following Specialty Compounds Requiring


the X-Compound Kneader Technology

> EPDM/EPR elastomer cable compounds


> Irradiated, cross-linked compounds
> Thermal resistant Silicone cable compounds
> Tailor-made blends and alloys for specific mechanical and
chemical resistance
> Additive blends used in the cable compounds
> Cable compounds with grafted chemistry

FURTHER
8 APPLICATIONS
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Control Systems & Service

Control Systems Service

X-Compound designs and builds complete control systems with X-Compound is your reliable partner for the supply of spare
visual displays for Turn key plants as well as for replacements or parts covering oscillating single screw compounders of nominal
supplements to existing plants. On request we also manufacture size up to 600 mm.
less sophisticated control systems.
X-Compound offers
The application of existing peripheral plant components as well as
their incorporation via Profibus network is also part of our standard > High quality, durable, and corrosion resistant
programme. - kneading elements
- barrel liners
Basically our control systems are designed as follows: A PC based - kneading teeth
Windows system which performs plant monitoring and controlling > All spare parts, e.g.
together with a programmable logic controller (PLC). The process - screw shafts
and the plant are visualised using a series of on-screen pages and - worm shafts
allowing interactive display and modification of current setpoint - lubrication pumps
values and alarms. - process chamber sealing systems
- die plates
- pelletizing knife arms
> Interchangeable kneader barrels completely refurbished
and guaranteed
> Any individual part for gear boxes or complete
interchangeable gear boxes, all guaranteed

Our spare part service is well-known for

> High quality


> Low prices
> Short delivery times

CONTROL SYSTEMS
& SERVICE 9

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Technical Data

X-Compound Kneader Discharge Unit

Technical Data Screw Process Speed Max. drive Screw Process Max. drive
diameter length max. power diameter length power
Type mm L/D rpm kW mm L/D kW

CK 45 45 8 - 24 500 30 55 6 15

CK 90 98 8 - 24 500 250 140/150 6 75

CK 120 120 8 - 24 500 350 160 6 80

CK 150 150 8 - 24 500 650 200 6 150

CK 200 200 8 - 24 500 1200 250 6 300

PVC
HFFR Semicon XLPE XLPE Black Insulation/
Process Data Silane peroxide Jacketing sheathing/
bedding

Process length [L/D] 16 - 22 18 - 24 12 - 16 12 12 12

Spec. energy [kWh/kg] 0,07 - 0,12 0,15 - 0,25 0,2 - 0,3 0,12 - 0,16 0,15 - 0,25 0,06 - 0,08

CK 45 20 - 40 40 - 70 40 - 80 40 - 60 40 - 80 70 - 110

CK 90 300 - 600 350 - 700 500 - 800 500 - 800 500 - 800 700 - 1400

CK 120 450 - 800 500 - 900 600 - 1000 800 - 1200 600 - 1000 1000 - 1800

CK 150 800 - 1500 900 - 1600 1000 - 1500 1400 - 1900 900 - 1600 2500 - 3500

CK 200 1500 - 2800 1800 - 3000 1700 - 2200 2000 - 2800 1800 - 3000 3500 - 5500

Subject to change without notice.

10 Technical Data
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X-Compound GmbH TROESTER Machinery TROESTER Machinery, Ltd. TROESTER Moscow TROESTER GmbH & Co. KG
Hardmatt 932 (Shanghai) Co., Ltd. 300 Loomis Avenue RUS-Moscow, 109815 Am Brabrinke 1-4
CH -5082 Kaisten, Switzerland Workshop No. 1, Area C Cuyahoga Falls, Ohio 44221, USA Phone +7-495-76014233 30519 Hannover, GERMANY
Phone +41-62-869 10 30 No. 6999 Chuan’sha Road, Pudong Phone +1-330-928-7790 E-mail lusia13710@mail.ru Phone +49-511-87040
Fax +41-62-874 32 08 Shanghai 201202, PR CHINA Fax +1-330-928-7239 Fax +49-511-864028
E-mail info@x-compound.com Phone +86-21-58598308 E-mail info@troester-usa.com E-mail innovations@troester.de
www.x-compound.com Fax +86-21-58598310 www.troester-usa.com www.troester.de
E-mail info@troester.cn
www.troester.cn

X-COMPOUND 2013/03 · 250 · E © TROESTER GmbH & Co. KG 2012. Only the contract between the customer and X-COMPOUND is binding for any guarantees and commitments. The particulars
given herein do not represent promises of any special characteristics. They serve purely for general information purposes and may differ in individual cases. No claims of any nature may be derived
herefrom. The observation of commercial trade marks or patents shall in every instance be the responsibility of the customer.

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