Cable extrusion

Sampsistemi 1
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Automotive wire insulation
4
Electronic and Building wire insulation
6
Building wire sheathing
8
Sheathing with SZ process
10
Power cable insulation
12
Let your production soar Power cable sheathing

Sampsistemi supplies a complete range of

14
at a glance
machines and equipment for the wire and cable
LAN & Telephone wire insulation
production, according the highest request of market + Wide production range of complete
based on different applications. Manufacturing lines
16
solutions are characterised by top linear speeds
+ Non-stop production during cable
and guarantee minimal energy dispersion. The Coaxial cables
type changeover and colour
outstanding versatility is based on an extensive
range of extruders, designed to process different
changing 18
+ High production speed
types of materials including elastromers, silicone,
+ Energy consumption savings High Temperature lines
thermoplastic, cross link polyethylene (XLPE),
halogen-free and fluoridated products. + Production savings through 20
The highly innovative extrusion solutions feature: optimised process solutions
+ Chameleon technology + Highest melting quality thanks to Fiber Optical cable lines
+ G screw for PVC – PE and HFFR/HL0S accurate temperature control 22
+ “0” scrap solution with quick colour systems
change system + Production flexibility thanks to lines Rubber lines
+ PE cross-linking (XLPE) with catalyst, engineered for different materials
liquid silane and CV tube + Long-lasting extrusion screws &
24
+ Chemical and physical expansion processes for barrel made by anti-wear materials
polyethylene, polypropylene and fluoropolymer Silicone lines
+ Wide range of extruders in order to
+ Silicone curing solution with high production follow all market requirements 25
speed + Fast PLC network line management
+ Line featuring specific software Extruder technology
Systems are personalised to meet specific
requirements. All our solutions can be easily
+ User-friendly HMI (Human Machine 26
Interface)
integrated into your existing production line and + Integration of all main OEM as Unwinding & Winding solutions
control system. Our engineering team is at your
disposal to provide you with innovative, highly
cable quality instruments,
loading/dosing/drying systems,
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productive manufacturing solutions.
cable marking and labelling units
Software solutions & Services
34
Sampsistemi 2 Sampsistemi 3
Automotive wire insulation lines
A

TX 6 V2
Pay offs Braking Extruders Extrusion Vulcanization Cooling Take-ups Coiler System
system heads group troughs Dual Auto supervisors
SV 630 CD FR 300 I SAMP 35-25 TX 6 D TU 5 VO VR 7 T/C AV 560 D MD 330 SU L
SV 800 CD SAMP 45-25 TX 6 V AV 630 D SU P
SV E 800 DM SAMP 60-25 TX 6 V2 Wire dryers
SAMP 80-25 TX 6 DL WD 7
SAMP 80-25L TX 6 VL WD 12 Horizontal extrusion group Cross-head with 2 X-Flow systems

High-speed automotive wire insulation lines engi- Line types

neered to produce low voltage automotive cables. AI A1: with 2 extruders, for stripe/skin process
It is possible to insulate T3 classification standards AI A3: with 3 extruders, for stripe/skin quick colour change
using thermoplastic materials and cross linked flame- AI A4: with 4 extruders, for stripe/skin and insulation quick
retardant polyethylene (XLPE and HFFR). colour change Conductor Conductor section Wire Ø, max. Insulation Speed, max.
AI V1: horizontal vulcanization with 2 extruders Bunched (Class 5) 0.13 - 7.0 mm² 5 mm PVC, PE, XLPE, 1500 m/min
Automatic colour change of insulation, skin and AI V3: horizontal vulcanization with stripe/skin quick colour
stripe with minimum scrap and at the maximum pro- HFFR, PP, PPE, TPE
change
duction speed, without slowdown.

at a glance
+ Chameleon technology: Non-stop production
during cable type changeover
+ Quick colour change process without scrap
AI V3

+ Easy and quick extruder group feeding

+ High production quality by extruder group
optimization
+ In-line coiling (MD 330) without production
speed reduction
+ Automatic colour change with 2 extruders only

Extrusion group for vulcanization line with

automatic stripe colour change system Quick colour change process Chameleon technology: product changeover at
max speed without line stop

Sampsistemi 4 Sampsistemi 5
Electronic and Building wire insulation lines

Pay-offs Braking Rod break- Extruders Cooling External Take-ups Take-ups System
systems down machine troughs capstan single Dual Auto supervisors
SV L FR 300 I R1 SAMP 35-25 VR 7 T/C MC 600 AV 800 AV 560 D SU L
SV (E) 800 DM FR 500 I R2 SAMP 45-25 VR 12 T/C TC 600 AV 1250AV 630 D SU P
SV (E) 1250 DM FR 500 M SAMP 60-25 AV 800 D
Annealers SAMP 80-25 Wire dryers Accumulator Dual Auto AV 1000 D
SV 630 CD AH(V) 3500 SAMP 100-25 WD 7 AC 400 V AS.A 630 AV 1250 D
SV 800 CD AH(V) 4200 SAMP 120-25 WD 12 AC 600 V AS.A 800
SV 1000 CD AH(V) 5000 AC 600 H AS.A 1000
SV 1250 CD

Engineered to insulate low-voltage wire with various Line types

thermoplastic materials including flameretardants
such as reticulated polyethylene and halogen-free
compounds.
The range is completed by THHN cable manufacturing
equipment where cables are jacketed with nylon.
Electronic
WI A1: 1 and 2 extruders for skin/stripe process
WI A2: engineered for HFFR materials
SV 800 CD R1
1 AV 630 D
WI A3: 3 extruders for stripe/skin quick colour change
Building
BI A1: 1 and 2 extruders for skin/stripe process
BI A2: 2 extruders, high productivity
BI A3: 3 extruders for stripe/skin quick colour change
BI A4: THHN wire insulation and sheathing
BI A4-HS: THHN wire insulation and sheathing in line with rod

WI A1
Extrusion group for wire production at 1500 m/min
break-down machine

with line supervisor touch panel model SU L at a glance

Dual flyer pay-off Rod breakdown machine Dual automatic take-up
+ High productivity line:
• Chameleon technology:
Non-stop production during cable type changeover
• No production speed reduction during reel changeover
• One extrusion screew for many materials
• “0” scrap with quick stripe/skin colour change system
+ Flexibility with wide insulation material range Conductor Conductor section Wire Ø, max. Insulation Jacketing Speed, max.
+ Compact design
Solid (Class 1), 0.3mm - 35.0 mm
2 2
Electronic: 5 mm PVC, PE, XLPE, PA 1500 m/min
+ Material saving thanks to accurate dosing process
+ No foundations required Stranded (Class 2), Building: 12 mm XLPE Liquid Silane, 2400 m/min*
+ One step solution with In-line drawing machine Bunched (Class 5) PP, HFFR,
+ High production quality by extruders group optimization PUR, TPE
+ Wide reel range
+ Line compact design * Tandem with rod breakdown machine

Sampsistemi 6 Sampsistemi 7
Building wire sheathing lines

PT 2240
Pay offs Extruders Cooling Pulling Accumulators Take-ups System
troughs elements Horiz. / Vertical Single / Dual supervisors
SV (E) 800 DM SAMP 35-25 VR 30 C/T MC 800 AC 600 H/V AV (2x) 1000 SU L
SV (E) 1250 DM SAMP 45-25 TC 800 AC 800 H/V AV (2x) 1250 SU P
SV (E) 1600 DM SAMP 60-25 Wire dryers TR 800 C AC 1000 H AV (2x) 1600
PT 1600 / 1800 SAMP 80-25 WD 30 TR 1200 C PT 1600 / 1800
PT 2240 / 2500 SAMP 100-25 PT 2240 / 2500
SAMP 120-25
PT 2240 portal pay-off/take-up (10 tons)

Line types Process types

BS A1: for single layer process Single-layer: Conductor Cable Ø, max. Sheathing Speed, max.
BS A2: for filling and sheathing in one time application of sheathing with one extruder
Assembled 30 mm PVC, PE, 500 m/min
Co-extrusion: simultaneous application of:
filling and sheathing or filling, sheathing and skin cables XLPE, HFFR,
Tandem extrusion: PP, TPE
two extrusion groups, one for filling and one for sheathing

BS A1
Caterpillar
4000 N at 170 m/min

at a glance
+ Wide production range

TR 800 C
+ Wide range of insulation materials
+ Production flexibility with different reels sizes
+ Continuous working without line stop during reel
changeover

Extruder and cross-head with automatic by-pass

Sampsistemi 8 Sampsistemi 9
Building wire sheathing lines with SZ process
PATENTED

Pay offs SZ Extruders Cooling Pulling Accumulators Take-ups System

Groups troughs elements Horizontal Single / Dual supervisors
SV (E) 800 DM SZ 16 SAMP 35-25 VR 30 MC 600 AC 600 H AV (2x) 1250 SU L
SV (E) 1250 DM SAMP 45-25 VR 30 T TC 600 AC 800 H AV (2x) 1600 SU P
SV E 1600 DM SAMP 80-25 VR 30 CA MC 800
Filling cross-head
SV 800 CD SAMP 100-25 TC 800 PT 1600 / 1600
Stranding at the point of extrusion
SV 1000 CD SAMP 120-25 Wire dryer TR 800 C PT 2240 / 2500
SV 1250 CD SAMP 160-25 WD 30

Sampsistemi has patented a system for the high speed manufacture of flexible cables. Designed with a dedicated
TX 30 S
extrusion group, cables are practically stranded at the point of extrusion. Conductors and filler are then separated by a
fine layer of plastic material, meaning that traditional talc powdering stations are no longer required, with all the obvious
environmental advantages that this entails. A submerged torsion locker caterpillar keeps the cabling in place as the plastic
sheath cools immediately after the extrusion group.
It is therefore possible to keep the pitch and still produce at surprisingly high speed.

Process types
Co-extrusion: simultaneously filling and sheathing at a glance
Tandem extrusion: two extrusion groups,
one for filling and one for sheathing + One step production solution
(laying-up and sheathing)
Sheathing cross-head with tool guide
Line types + Flexible wire stranded SZ line at high speed
BS B1: SZ group, co-extrusion filling/sheathing system + Flexibility in production that allows the use of
BS B2: SZ group, 2 tandem extruders for tandem
filling/sheathing and filling/sheathing/skin
BS B3: SZ group with patented system
different materials
+ Full production speed during reel changeover
+ Wide reel range
AV 1600 D
and 2 tandem filling/sheathing extruders

BS B3
Extrusion group with
Sampsistemi patented SZ process
Dual Automatic take-up for continuous
production without line reduction speed

Conductor Conductor section Wire Ø, max. No. of wires, max. Filling Sheathing Speed, max.
Solid (Class 1), 0.5 - 16.0 mm² 30 mm 7 x 6 mm² EPDM, PVC, PE, 400 m/min
Stranded (Class 2), 5 x 16 mm² PVC, HFFR
Nose of SZ Bunched (Class 5) HFFR
stranding unit

Sampsistemi 10 Sampsistemi 11
Power cable insulation lines

Pay-offs Extruders Cooling Wire dryer Pulling Accumulators Take-ups System

troughs elements Horiz. / Vertical Single / Dual supervisors
SV (E) 1250 DM SAMP 35-25 VR 30 WD 30 MC 800 AC 600 H / V AV (2x) 1000 SU L
SV (E) 1600 DM SAMP 45-25 VR 30 T WD 50 AC 800 H / V AV (2x) 1250 SU P
PT 1600 / 1800 SAMP 60-25 VR 50 TC 800 AC 1000 H AV (2x) 1600
PT 2240 / 2500 SAMP 80-25 VR 50 T TR 800 C AC 1200 H PT 1600 / 1800
PT 3200 SAMP 100-25 TR 1200 C PT 2240 / 2500
SAMP 120-25 PT 3200
SAMP 120-32
SAMP 160-32 PI B1
Conductor Conductor section Wire Ø, max. Insulation Speed, max.
Engineered for high-speed insulation of Line types Solid (Class 1), 1 - 800 mm² 50 mm PVC, PE, 500 m/min
power cables. Depending on line com- PI A1: high-speed insulation line for conductors up to 120 mm² Stranded (Class 2), XLPE,
position it is possible to insulate cables PI A2: high-speed insulation line using HFFR for conductors up to 120 mm² Bunched (Class 5) XLPE Liquid Silane,
with traditional thermoplastic materials, PI B1: insulation line for conductors up to 800 mm²
flame-retardant halogen-free compounds PI B2: insulation line using liquid silanes HFFR, PP,
or liquid silanes. PUR, TPE

Caterpillar
unit 10000 N at 135 m/min
Extrusion group: 500m/min

at a glance
+ MULTIFLEX-25 for liquid silane
process with 25d extruder
+ High production line
• Non-stop production
• High production speed
• Full line speed during reel
changeover thanks to Dual
Automatic Take-up for
reels diameter up to 1600 mm
+ Wide cable manufacturing
range
+ Top quality final products
+ Operator friendly line
+ Excellent wire pulling units
TR 1200 C
Sampsistemi 12 Sampsistemi 13
Power cable sheathing lines

Pay-offs Extruders Cooling Wire Pulling Accumulators Take-ups System

troughs dryers elements Horizontal supervisors
PT 2240 SAMP 45-25 VR 50 ...T WD 50 TR 1200 C AC 800 H PT 2240 SU L
PT 2500 SAMP 60-25 VR 100 ...T WD 100 TR 1800 C AC 1000 H PT 2500 SU P
PT 3200 SAMP 80-25 VR 150 ...T WD 150 TR 2800 C AC 1200 H PT 3200
PT 4500 SAMP 100-25 VR 250 ...T WD 250 PT 4500
PT 5000 SAMP 120-25 PT 5000
SAMP 160-25

Engineered to apply sheath on round and flat assembled cables

with various thermoplastic materials.
The biggest line is engineered for HV cable sheathing also and
it suitable for working in tandem with different type of protecting
cable solutions like to tape applicator, lead extruder and bitumen
applicator.
Line types
PS A1: Basic sheathing line up to 60 mm
PT5000-50t
PS A2: Filling/sheathing line up to 60 mm
PS B1: Basic sheathing line up to 200 mm
PS B2: Filling/sheathing line up to 200 mm

Process types
Single-layer: sheathing application with one extruder
TR 2800 C PS B1
Co-extrusion: tandem filling and sheathing
Tandem extrusion: two extrusion groups,
one for filling and one for sheathing

Caterpillar unit 30000 N at 47 m/min HV sheathing line

at a glance
+ Tandemized solutions for
• Tape application (smooth & corrugated type)
• Lead application
• Bitumen application
+ High flexibility line Conductor type Cable Ø, max. Filling Sheathing Speed, max.
+ Wide cable manufacturing range Assembled cables 200 mm PVC, PVC, PE, 300 m/min
+ Continuous working during cutting process
+ High production speed SAMP 160-25
for 1600 Kg/h of HFFR
HFFR,
EPDM
HFFR, PP,
PUR, TPE

Sampsistemi 14 Sampsistemi 15
LAN & telephone wire insulation lines Solid PE / Chemical foam PE / Physical foam PE Insulation comparison
Copper 0.51 mm 0.51 mm 0.51 mm
Capacitance 218 pf/m 218 pf/m 218 pf/m
Insulation Solid Chemical foam Skin + Physical
process PE + skin + skin foam + skin
OD 0.915 mm 0.828 mm 0.780 mm
Foaming ratio 0 35% 60%

Pay-offs Drawing machines Extruders Extruders Cooling Take-ups System

with annealers for PVC & PE for FEP & PE troughs Dual Auto supervisors Skin thick. 0.05mm Skin thick. 0.05 mm Inner layer thick.
0.005 mm
SV F / R MT 250 RC 4AP SAMP 35-25 SAMP 35-25 F VR 7 T/C AV 560 D SU L Skin thick. 0.05 mm
SV 630 CD MT 250 RC 6AP SAMP 45-25 SAMP 45-32 F AV 630 D SU P Production speed 2,500 1,850 2,200
m/min MT 250 RC 4AP
SV 800 CD SAMP 60-25 SAMP 60-32 F PE weight kg/km 2.01 1.04 0.596
SV (E) 630 DM Skin-pass module SAMP 60-32 Wire dryers
SV (E) 800 DM SP 250 SAMP 80-25 WD 7 TI A1 Production sample with Sampsistemi line
SAMP 80-32 Foam/Skin process with chemical expansion

LI A1 - LI B1
LAN & telephone cable producers know the importance of Line types Foam/Skin and Skin/Foam/Skin processes
process stability and repeatability very well. TI A1: for telephone cables with solid PVC, solid PE and with physical foam expansion
With Sampsistemi lines, the setting-up is fast and rejects chemical PE foam Striping capability
are minimal due to standardised and harmonised line com- LI A1: for LAN cables with solid PE or physical PE foam Special pre-heating up to 200° C (LI B1)
ponents; indeed, drawing, annealing and pre-heating are LI B1: for LAN cables with solid FEP or physical FEP foam Skin pass module for the production of data cable
part of an avant-garde global system which includes the and solid PE or physical PE foam Extruder screw designed to reduce and keep melt pressure
LAN cable (Cat 6) with FEP
extrusion group, ergonomic cooling troughs and reliable constant at the gas injection point Process Foam/Skin + Stripe
dual spoolers. Stable automated extrusion process with limited fluctuations Cu Ø 0.51 mm
Moreover, customers also benefit from having a single sup- in capacitance and diameter O.D Ø 0.88 mm
plier and a single team of engineers who can flexibly work Nitrogen injection unit controlled by line supervisor Expansion 50 %
on the whole line during commissioning and service. Self-centering extrusion head, Line speed 500 m/min
with fine-tuning device for the best wire concentricity

LAN Telephone
at a glance Cores insulation Cat 5 e, 6, 7 and higher Std. Telecom
+ Top cable specification with single step production Conductor material Copper Copper
process (drawing, annealing and insulation) Ø Inlet wire (soft/hard) 3.0 / 2.7 mm 3.0 / 2.7 mm
+ Reduced set-up time Ø conductor 0.32 - 0.90 mm 0.32 - 0.90 mm
+ Low scrap material during start-up Cable Ø, max. 3.0 mm 3.0 mm
+ Excellent wire surface quality with conical
Insulation materials PE, PP, FEP PVC, PE
drawing cones
+ Self-centering extrusion cross-head with by-passes Process Solid and Physical Foam Solid and Chemical
+ Line centralised control with SU P supervisor Expansion level, max. 50% FEP 50% PE
LI A1

+ All line components are modularly engineered 70% PE

with the same Sampsistemi criteria Line speed, max. 3000 m/min 3000 m/min
+ Highly reliable dual automatic take-up with wire
Ø Tolerance ± 0.01 mm (for insulation ± 0.01 mm (for insulation
wraps protection during reel change-over
+ Wide range of take-up solutions thickness < 0.3 mm) thickness < 0.3 mm)
+ Easy maintenance ± 1% (for insualtion ± 1% (for insualtion
+ Reliable and accurate high pressure gas injection thickness > 0.3mm) thickness > 0.3mm)
unit with operator friendly interface Eccentricity tolerance F>0.96 F>0.95

Sampsistemi 16 Sampsistemi 17
Coaxial cable insulation lines CI A0
Cables insulated with fluoropolymers are traditionally used in aerospace, military
Production sample with Sampsistemi line

and nuclear applications, where a high level of fire resistance, good electrical
properties and exceptional chemical resistance are a priority.
Extrusion process parameters and the extremely high cost of fluoropolymers
have been an obstacle to their use in cable insulation. With longstanding experi-
ence in fluoropolymer technology, Sampsistemi has engineered a special ex-
trusion process which
Pay-offs Calibrating Extruders Extruders Cooling Pulling Take-ups System at a glance includes gas injection
trough for PVC & PE for FEP & PE trough element Dual Auto supervisors Micro-Coax cable (7x0.18 mm) with FEP
foaming. With this sys-
SV E 500 DM VT SAMP 35-25 SAMP 35-25 F VR 7 T/C/CA MC 600 AS.A 630 SU L + Flexibility with FEP and PE insulation tem insulating wire with Process Foam/Skin
+ Accurate melt temperature control fluoropolymers is no Skin thickness 0.05 mm
SV (E) 630 DM SAMP 45-25 SAMP 45-32 F VR 12 ...T AS.A 800 SU P Cu Ø 0.54 mm
+ Extrusion heads made from anti-wear materials more difficult than poly- O.D Ø 2.08 mm
SV (E) 800 DM SAMP 60-32 SAMP 60-32 F AV 560 D ethylene insulation. CAPAC 58 pF/m
SAMP 80-32 Wire dryer AV 630 D Expansion 54 %
Line speed 220 m/min
WD 12 AV 800 D
CI A1 - CI A2
Mini-coax cables, CATV cables and radio-frequency cables are primarily char-
acterised by their electrical impedance and the speed with which signals are
propagated. The common denominator of both signal propagation and dielectric Production sample with Sampsistemi line

Mini and micro-coaxial cable constants is the cable insulation material.

Nowadays, market demand requires very low dielectric constants which can only
insulation lines: be achieved by physical foaming extrusion processes. With a wealth of experi-
Foam/skin & ence in physical foaming by nitrogen injection, Sampsistemi lines can obtain a
Skin/Foam/Skin processes dielectric constant of 1.2, which corresponds to a polyethylene foaming degree
of 81%.
Other important cable parameters, such as low attenuation and structural return
Line types
loss, require extremely high Coax cable RG 59 with PE
CI A0: insulation line for micro-coax cables with FEP and PE
CI A1: insulation line for mini-coax cables with SRL frequency up to 1 GHz at a glance precision from all extrusion
line components, since it is Process Skin/Foam/Skin
CI A2: insulation line for mini-coax cables with SRL frequency up to 3 GHz Gas compressor for max 700 bar Cu Ø 0.816 mm
+ Structural return lost frequency up to 3 GHz necessary to achieve a line O.D Ø 3.59 mm
2

+ Wire calibrating device speed stability of 1/10000 CAPAC 52 pF/m

without extruder output Expansion 70 %
at a glance + Cable tension accuracy Impedance 75 Ohms
pulsing: no problem for
+ Accurate melt flow control
Sampsistemi lines!
+ High productivity line
+ Top cable quality (surface, expansion level and concentricity)
+ Fast line set-up
+ Low scrap material during start-up CI A0 CI A1 - CI A2
+ Striping capability Conductor Soft copper Soft copper
+ Extruder screw designed to reduce and keep melting pressure constant Copper clad aluminium Copper clad aluminium
at the gas injection point Copper clad steel Copper clad steel
+ Stable automated extrusion
Conductor Ø 0.2 - 3.1 mm 0.64 - 2.9 mm
+ Self-centering extrusion cross-head with fine-tuning device and by-passes
+ All line components are modularly engineered with the same Cable Ø, max. 7 mm 12 mm
Sampsistemi criteria Insulation material FEP, PE, PP PE, PP
+ Line centralised control with SU P supervisor Expansion level, max. 75% PE 81 % PE
+ Wide range of take-up solutions 55 % FEP
+ Highly reliable dual automatic take-up with wire wraps protection during
Line speed, max. 700 m/min 300 m/min
reel change-over
+ Easy maintenance Ø Tolerance ± 0.01 mm (for insulation thickness < 0.3 mm) ± 2.0 % (for insulation thickness < 5 mm)
+ Reliable and accurate high pressure gas injection unit with operator ± 1.0 % (for insualtion thickness > 0.3 mm) ± 1.5 % (for insualtion thickness > 5 mm)
friendly interface Eccentricity tolerance F>0.95 F>0.94

Sampsistemi 18 Sampsistemi 19
High Temperature insulation lines

Pay-off Wire Extruder for Extruder for Cooling Pulling Accumulator Take-up Line
pre-heater Fluoropolymers Thermoplastics Trough element Horiz. / Vertical Single / Dual supervisor
SV 630 DM PH-W SAMP 35-25F SAMP 35-25 VR 7 T/C MC 600 AC 400 H / V AV 2x630 SU L
SV 800 DM SAMP 45-25F SAMP 45-25 VR 12 T/C MC 800 AC 600 H / V AV 2x800 SU P
SV 1250 DM SAMP 60-25F SAMP 60-25 VR 30...T TC 600 AC 800 H / V AV 2x1000
PT 1250 SAMP 80-25F SAMP 80-25 TC 800 AV 2x1250
Wire Dryer PT 1250
WD 12
WD 30
PT 1600
HT A1
Conductor type Conductor section Wire Ø Max Insulation (material) Speed max
Automotive, aerospace and submerg- quality level of your final product. Line types
ible pump cable applications require A homogenized insulation with the re- HT A1: for max cable dia. 6 mm Tinned – Cu 30 AWG (0.05 mm2) 18 mm TPE, PEEK, FEP, 150 m/min
insulation materials with tempera- peatability of electrical and mechani- HT B1: for max cable dia. 18 mm Silver – Cu, to 4/0 AWG (107 mm ) 2
ETFE, X-ETFE, 300 m/min
ture resistance of more than 200°C cal cable performance is guaranteed Nickel – Cu PFA, MFA
(approx. 400°F). by an accurate line temperature con-
The Sampsistemi Extruders are par- trol system that manages the several
ticularly suitable for these materials thermo-regulated zones present in the
and allow you to improve your produc- line as much as the insulation adhe-
tion capacity guaranteeing the highest sion on conductor.

HT B1
at a glance
+ Excellent final product quality
+ Concentricity more than 95%
+ Insulation integrity
+ Surface homogeneity
+ Easy line set-up
+ Low material scrap
+ Non-stop production during
reel changeover
+ Centralized data process
control with accurate
management of all production
information
AV 2x1000
Sampsistemi 20 Sampsistemi 21
Fiber optical cable extrusion line

Pay-offs Extruders Cooling Wire Dryer Pulling Accumulator Take-up System

trough elements Horiz. / Vertical supervisor
SV (E) 800 DM SAMP 45-25 VR 7... T WD 12 MC 600 AC 400 H / V AV 1250 SU L
SV (E) 1250 DM SAMP 60-25 VR 12... T WD 30 MC 800 AC 600 H / V AV 1600 SU P
SV (E) 1600 DM SAMP 80-25 VR 30... T WD 50 AC 800 H / V PT 1600/1800
PT 1600 / 1800 SAMP 100-25 TR 800 C PT 2240
PT 2240 TR 1200 C

Engineered for coating and sheathing Line types

cables with high speed transmission
capacity.
These lines are suitable to produce
loose tube, tight buffer and drop wire.
OS DR: drop sheathing line at a glance
OS TC: tight buffering coating line
OS T1: tight buffering sheathing line + Different compounds extruded
OS LT: loose tube sheathing line with the same line
+ Single & double layer available
+ Best cable quality
+ Tailor-made solution
+ Wide cable manufacturing
program

OS TC
+ Durable machines
+ Operator friendly
+ Ample range of winding &

OS DR unwinding solutions Production speed 450 m/mm

Extrusion group: 200 m/min

TV.FO.318
max 500 m/mm
Aramid server
18 reels rotating pay-off for dropping sheathing line

Sampsistemi 22 Sampsistemi 23
Rubber insulation and sheathing lines Silicone insulation and sheathing lines

Pay-offs Extruders Curing Wire Pulling Accumulator Take-up System

system Dryer elements Horiz. / Vertical Single / Dual supervisor
Pay-offs Extruders CV tube Wire Pulling Accumulator Take-up System
Dryers elements Horiz. / Vertical Single / Dual supervisor SV (E) 1250 DM SAMP 45-15D FV - FVR WD 12 MC 600 AC 400 H / V AV 1250 SU L
SV (E) 1600 DM SAMP 60-15D TU 5 VO WD 30 MC 800 AC 600 H / V AV 1600 SU P
SV (E) 1250 DM SAMP 45-18D TU 5 VO WD 12 MC 600 AC 400 H / V AV 1250 SU L PT 1600/1800 SAMP 80-15D TU 30 VO WD 50 AC 800 H / V AS.A 800
SV (E) 1600 DM SAMP 60-18D TU 30 VO WD 30 MC 800 AC 600 H / V AV 1600 SU P PT 2240 SAMP 100-15D TR 800 C AS.A 1000
PT 2240 SAMP 80-18D WD 50 AC 800 H / V AS.A 800 SV 630 CD SAMP 120-15D TR 1200 C AV 2x1250
SV 630 CD SAMP 100-18D TR 800 C AS.A 1000 SV 800 CD SAMP 160-15D PT 1600
SV 800 CD SAMP 120-18D TR 1200 C AV 2x1250 SV 1000 CD PT 2240
SV 1000 CD SAMP 160-18D PT 1600
PT 2240

Engineered for the insulation and sheathing of cables with
rubber (elastomers) by means of molten salt curing sys-
tems or horizontal vulcanizing (CV) tubes with steam.
Thanks to the accurate temperature control of our solu-
tions we can cover all market needs in terms of different
rubber types and customer production programs.
Line types
BI V1: CV insulation line for conductor up to 25 mm2
PI V1: CV insulation line for conductor up to 300 mm2
BS V1: CV sheathing line for cable diameter up to 30 mm
PS V1: CV sheathing line for cable diameter up to 30 mm
Engineered for the insulation and sheathing of cables with sili-
cone rubber by means of molten not pressurized salt curing sys-
tems.
Thanks to our solution we can process all silicone types obtain-
ing a very versatile line.
Line types
WI S1: silicone insulation line for conduptor up to 6 mm2
BI S1: silicone insulation line for conduptor up to 25 mm2
PI S1: silicone insulation line up to 300 mm2
BS S1: silicone insulation line for cable diameter up to 30 mm

PI V1
Extrusion group: 200 m/min
WI S1
Extrusion group: 500 m/min

at a glance
at a glance + Different silicone types
produced with the same line
+ Different rubber types produced with the same line
+ Single & double layer
+ Single & double layer with stripe
with stripe
+ Flexible solutions for rubber supplied in stripes
+ Best cable quality
and granules
+ High production speed
+ Best cable quality
+ Wide cable manufacturing
+ Wide cable manufacturing program
program
+ High production speed
+ Operator friendly
+ Operator friendly
+ Ample range of winding &
+ Ample range of winding & unwinding solutions
unwinding solutions

Sampsistemi 24 Sampsistemi 25
Extruder technology –
the core of extrusion knowhow
A fundamental part of any high per-
formance line, Sampsistemi extruders
are born from the longstanding expe-
rience and commitment of our expert
team of engineers. Our extruders are
renowned for their high levels of pro-
ductivity and flexibility. Sampsistemi
extruders answer to any requirement
from high speed cable insulation
to skin/stripe processes, automatic
colour change systems, sheathing
lines.
Top output values at low
melt temperatures and high
back pressures
Excellent output stability is assured by
a forced feeding zone and an accu-
rate screw design.
An optimised L/D ratio ensures
smooth plasticization of thermoplas-
tic compounds with top output values
(up to 1600 kg/h).
SAMP 120
at a glance
+ From 6% up to 33% more
productivity than current
technology
+ High performance temperature
control resulting on shorter
ramp-up time
+ Virtual “0” scrap material
+ Accurate dosing system
+ Automatic cleaning capabilities
+ High torque AC drive:
SAMP Powerpack™
Sampsistemi 26
Linearity – Perfect output
across all screw speed
ranges
As output per screw revolution is the
same for all screw speed ranges, it
suffices to pre-set rpm according to
insulation thickness and cable pro-
duction speed to keep product diam-
eter within tight tolerances, both dur-
ing acceleration and deceleration.
Reliability
High quality pays off!
We conceive our machines with a
view to constantly cutting mainte-
nance costs.
We utilise top quality resistant com-
ponents. Totally reliable reducers and
excellent barrel and screw surface fin-
ishes are all absolute musts at Samp-
sistemi and ensure that you produce
efficiently over time.
CHAMELEON CV Line
Chameleon is a revolutionary solution that allows
the cable type changeover from a striped cable
Changeover time
to a non-striped one and vice versa in just a few
seconds, without stopping the production line and
at a glance disassembling the extrusion head. 180
min
Standard Insulation Line
+ Barrels with a forced feeding This technology is suitable for all SAMP extrusion
zone Line with Chameleon
heads. 45
+ Barrels made from nitrited steel min 1 min
to increase hardness and 500 €
at a glance
N
lower wearing
o
pr
+ Barrel thermoregulation by means
od
22.500 €
u ct
of electrical heaters and fans + Non-stop production
io
n
va
+ Screws made from nitrited steel + High quality of the final product
lu
e
+ Screw profiles optimised to barrels + Wide application range
+ Stable & accurate thermo- + No maintenance for striping process
regulation + Less cross-head components average wire cost: 0,50 € / m
+ Fast line set-up thanks to (no single layer distributor is needed) production speed: 1000 m/min 90.000 €
reduced preheating time
+ Efficient & quiet barrel cooling
+ Monitored melt pressure to
G SCREW
prevent barrel overpressure
+ Automatic crosshead clamping
Insulation material changeover time
+ User-friendly process supervision
for quick and simple product at a glance
changes + Flexibility (many insulation materials with one screw only)
4h + High reduction time for insulation material changeover
(4 times less than traditional technology)
+ No downtime for screw extraction
1h + Only one screw for all materials
+ High productivity (same output compared to dedicated screws)
Standard Screws G Screw
MULTIFLEX 25
Liquid Silane and not only
at a glance
+ A single machine for all
thermoplastic materials
+Liquid silane and HFFR / LS0H
materials with the same extruder
+ Maximum fllexiblity in production
with less investment
+ Easy installation
+ Fast material changes
for 1200 Kg/h of HFFR + Future-safe investmens
Sampsistemi 27
Low voltage and telecom extruders For Elastomers
Extruder size Motor No. of thermoregulated Screw max.
type zones rpm
For thermoplastic compounds
SAMP 45-18 AC 2 80
Extruder size Motor No. of thermoregulated Screw max. Accessories SAMP 60-18 AC 3 70
type zones rpm
at a glance SAMP 80-18 AC 3 60
SAMP 35-25 AC 3 220 SAMP 100-18 AC 3 50
SAMP 45-25 AC 4 200 + Screw thermoregulation unit SAMP 120-18 AC 4 44
SAMP 60-25 AC 4 150 + Automatic cross-head clamps SAMP 120-20L* AC 4 80
& by-passes
SAMP 80-25 AC 5 120 SAMP 160-18 AC 4 36
+ Master-batch colour and
SAMP 100-25 AC 5 100 catalyst dosing units *Suitable for EPDM and PVC
SAMP 120-25 AC 5 80 + Gravimetric compound
SAMP 160-25 AC 5 60 dosing station
+ Compound dryers
+ Various compound loading
systems
For liquid silane*
+ In-line cable quality control
Extruder size Motor No. of thermoregulated Screw max. systems
type zones rpm
SAMP 120-32 AC 6 80
SAMP 160-32 AC 6 60

* It is possible to extrude liquid silane with 25 Ø extruders by using MULTIFLEX 25 For Silicone
Extruder size Motor No. of thermoregulated Screw max.
For physical foaming type zones rpm
SAMP 45-15 AC 2 80
Extruder size Motor No. of thermoregulated Screw max.
type zones rpm SAMP 60-15 AC 3 70
SAMP 80-15 AC 3 60
SAMP 45-32 AC 5 200
SAMP 100-15 AC 3 50
SAMP 60-32 AC 5 150
SAMP 120-15 AC 4 44
SAMP 80-32 AC 6 120
SAMP 160-15 AC 4 36

For fluoropolymer compounds

Extruder size Motor No. of thermoregulated Screw
type zones max. rpm
SAMP 35-25F AC 3 220
Barrels, screws and
SAMP 45-25F AC 4 200
cross-head clamps made of
SAMP 45-32F AC 5 200
corrosion-resistant materials
SAMP 60-32F AC 5 150
SAMP 60-25F AC 4 150 Special high-performance
SAMP 80-25F AC 6 120 ceramic heating elements for
barrel temperatures up to 500°C

Sampsistemi 28 Sampsistemi 29
Complete your line with Dual flyer
Sampsistemi unwinding & winding solutions pay-offs

Sampsistemi offers a wide range of

wire & cable unwinding and winding Product range
machines. We design our solutions
adapted to the specifics of your prod- at a glance
uct and process.
+ High-speed dual flyer pay-off
+ Dual automatic take-ups for SV 630 CD + High speed unwinding
continuous working without Reel flange Reel flange Reel weight
Our pay-offs and take-ups are de- + Automatic wire change
reduction speed Ø [mm], max. Ø [mm], min. [kg], max.
signed for maximum rigidity and sta- + Welded wire detection
+ Self traversing portal pay-offs
bility to conveniently employ even SV 630 CD 630 400 600 + Easy handling
large reels reliably. Fastest speeds and take-ups up to 70 tons
SV 800 CD 800 560 1200 + Easy installation
and easy reel change contribute to + Single motorised pay-offs and
SV 1000 CD 1000 500 2500 + Fine tuning cones
the profitability of your extrusion line. take-ups
+ On board electrical equipment
SV 1250 CD 1250 630 4500
MD 330: Automatic Dual Coiler
A variety of safety features, supported
Max coil dia: 330 mm
by thorough testing and strict quality
protocols during assembly and run-off,
guarantee operator's safety in daily
Single shaft pay-offs and take-ups
production.
Pay-offs Take-ups Reel flange Reel flange Reel Weight
Ø [mm], max. Ø [mm], min. [kg], max.
LIGHT
S.FO 400 410 235 20
S.SB.F/M 630 AMS 630 630 400 300
S.SB.F/M 1000 AMS 1000 1000 600 600
S.SB.F/M 1200 AMS 1200 1200 800 1000

Single motorised pay-offs & take-ups

at a glance
+ High speed
+ Quick reel handing
+ Low preventive maintenance
+ Easy installation

SV
V E 800
0 DM
Pay-offs Take-ups Reel flange Reel flange Reel weight
Ø [mm], max. Ø [mm], min. [Kg], max.
SV E 500 DM 500 255 450
SV E 630 DM 630 315 650
SV E 800 DM AV 800 800 450 1200
SV E 1250 DM AV 1250 1,250 630 2600
SV E 1600 DM AV 1600 1,600 800 4000

Sampsistemi 30 Sampsistemi 31
Self-traversing portals Dual automatic take-ups for continuous working
for pay-off & take-up
at a glance
AV 1250 D
at a glance
+ Space-saving
+ Minimum setup time
+ Maximum change-over reliability at full speed
+ Self-centering pintles
+ Energy consumption saving
+ Wide range of reels
+ Easy integration to existing extrusion line
+ Accurate cable distribution
+ Low preventive maintenance
+ Safe operation
+ Automatic reel loading/unloading system
+ Easy & intuitive HMI
+ Long inner wire end capability
+ Both Driving Wheel type
+ No foundations required
and Dog Pin type are available
+ Carefree maintenance

AA.FO.400 AV 560 D AV 630 D AV 800 D AV 1000 D AV 1250 D AV 1600 D

Flange Ø, max. mm 410 560 630 800* 1000** 1250 1600
Flange Ø, min. mm 235 400 450 500 560 800 1000
Width, max. mm 265 425 475 600 750 950 1180
PT 1600 PT 1800 PT 2240 PT 3200 PT 3600 PT 4500 PT 5000 Weight, max. kg 20 200 350 550 1200 2000 4200
Flange Ø mm 800 - 1600 630 - 1800 1000 - 2240 1600 - 3200 2000 - 3600 2600 - 4500 3000 - 5000 Speed, max. m/min 500 3000 2500 1200 1500 1500 600
range (Opt. 2500)
Weight, max kg 6000 8000 10000 20000 30000 40000 50000/70000 * suitable for 36’’
Speed, max m/min 400 300 300 200 100 40 20 ** suitable for 42’’

Automatic coiler
at a glance
Dual automatic take-up series
+ In-line coiling
with reel shaft trolley
+ Maximum change-over reliability at full speed
+ No reel for delivery AS.A 630 AS.A 800 AS.A 1000
+ Easy integration with existing extrusion line
Flange Ø, max. mm 630 800 1000
Flange Ø, min. mm 400 600 800
Bunched wire section mm2 0.22 - 4.00 Width, max. mm 475 600 780
Insulated wire Ø mm 0.50 - 3.60 Weight, max. kg 300 400 800
Coil Ø, max. mm 330 Speed, max. m/min 600 600 500
Coil inner Ø, min. mm 100
Coil outer width, max. mm 100
Speed, max. m/min 1200

Sampsistemi 32 Sampsistemi 33

Software solutions for easy and fast operation,
avoiding non-productive auxiliary times
Integration and control
SAMPSYS Software package controls
and integrates all single units into our
manufacturing line.
Get an overall picture of the line per-
formance by measuring production
availability, performance and quality
and gaining control of your complete
manufacturing process.
Future safety
Our software is modulary built
ensuring flexible and fast upgrades of
single modules.
Sampsistemi 34
System functions
+ Data logging
+ Statistical process control
+ Alarm functions
+ Process parameter memory
+ Scheduler for production timing
+ Reporting with pre-configured
templates
+ Monitoring of line status and
performance characteristics of
each single unit
+ Easy data export
+ Tele-maintenance through phone
line and modem for diagnostics
upgrades and operational help
+ System recovery
+ Help function
+ User administration matrix
+ Production history
+ Maintenance interval setting and
administration
1 2
3 4
at a glance
SAMPSYS line control concept
for quality and production
management featuring:
+ Meeting the Industry 4.0 std
+ Complete line control
+ Process supervision
+ Networking and
interfacing with existing lines
+ Wealth of automised process
and control functions
+ User friendly HMI
(Human Machine Interface)
+ Better productivity and
efficiency
+ Teleservice for trouble
shooting savings
+ Wide touch screen 19”
The key to success:
Overall equipment efficiency
Planning
and analysis
Sampsistemi analyses your produc-
tion requirements and recommends
solutions for the demanded produc-
tivity and quality. Whether you need a
single machine or a complete line, we
are your one-stop source for your wire
and cable manufacturing project.
Service plans
Our scheduled service help you avoid
unexpected problems and keep your
line productivity and the quality of the
finished product at maximum levels.
Technology development
programs
When you require specific solutions
we listen closely in order to satisfy
your needs to even beat your expec-
tations.
+ Availability
+ Performance
+ Quality
Our experience in the area of
designing manufacturing equip-
ment and supporting production
processes let you exploit your
equipment to the maximum,
reaching new levels of productivity
by optimising equipment
availability, performance and
quality.
Connect to
worldwide service
Stay connected with superior prod-
uctivity. The closest Sampsistemi
Operator training service centre supports availability,
precision, speed and productivity of
Trained operators let you exploit your
your manufacturing line.
manufacturing lines to the maximum
while avoiding down-time and secur-
ing carefree manufacturing. at a glance
Continuous improvement + Guaranteed OEM quality
through the lifecycle of your
Ongoing research and development
production equipment
effect new products but flow also into
+ Continuous process
component design which can en-
improvement
hance existing lines and units.
+ Complete project responsibility
from one supplier
On-call service
+ Spare Parts
In case of emergencies we stand by + Revamping: mechanical and
to get you back running, if online ser- electrical
vice is not sufficient. + SW updates and upgrades
Sampsistemi 35
HQ Sampsistemi
Via Saliceto, 15
40010 Bentivoglio (BO)
Italy
T: +39 051 63 19 411
F: +39 051 37 08 60
info@sampsistemi.com

Sampsistemi Extrusion Sampsistemi Sampsistemi SAMP USA

Strada Prov. Busto Cassano, 3 Via Aldo Moro, 13 Via dei Mestieri, 8 10522 Governor Lane Blvd.
21054 Fagnano Olona (VA) 36060 Pianezze (VI) 20863 Concorrezzo (MB) Williamsport, MD 21795
Italy Italy Italy USA
T: +39 0331 66 13 40 T: +39 0424 47 20 84 T: +39 039 90 54 500 T: +1 (301) 22 38 584
F: +39 0331 66 92 21 F: +39 0424 72 780 F: +39 039 90 54 540 F: +1 (301) 22 38 542
info@sampsistemi.com info@sampsistemi.com info@sampsistemi.com info@sampinc.com

SAMP India Cable Machines
CTS No. 770/5,”Alankar”, Ground Floor
Behind Sane Dairy, Off Bhandarkar Road
Lane No.7 ShivaJinagar, Pune 411 004
India
T: +91 98 9017 5689
M (IT): +39 366 6917 649
india@sampsistemi.com
Sampsistemi Changzhou
No. 10 Fukang Road, Xinbei District,
Changzhou, 213000 Jiangsun Province
China
T: +86 519 854 83 550
F: +86 519 854 83 557
info@cn.sampsistemi.com
Sampsistemi Shanghai Sales Office Sampsistemi CIS
The Cross Region Plaza Building Anatoliy Abrosimov
Room 19E, Floor 19th T: +7 499 2358 952
No. 899 Lingling Road, Xuhui District M: +7 919 410 30 50
Shanghai, China a.abrosimov@sampsistemi.it
T: +86 21 6439 8416
info@cn.sampsistemi.com

Setic Pourtier Cortinovis do Brasil Indústria e Euroalpha RM

126, Rue de Matel Parc de l’Esplanade, Comércio de Máquinas Via Aldo Moro, 13
42300 Roanne 1 rue Enrico Fermi Avenida Piraporinha, 1073-G10 36060 Pianezze (VI)
Sampsistemi_Extrusion_en_v012

France 77400 Saint Thibault des Vignes
T : +33 4 77 23 2555 France
F : +33 4 77 71 1085 T: +33 1 6421 8400
setic@fr.sampsistemi.com F: +33 6426 6110
pourtier@fr.sampsistemi.com
São Bernardo do Campo (SP) Italy
09891-000 - Brazil T: +39 0424 47 20 84
T: +55 (11) 43 41 51 11 F: +39 0424 72 780
F: +55 (11) 43 41 87 87 info@sampsistemi.com

www.sampsistemi.com www.sampspa.com

Sampsistemi 36