Against the backdrop of surging global PV installed capacity, the industry faces explosive demands for capacity expansion and quality upgrading of specialized photovoltaic cables. Jiangsu Handing Cable Equipment has unveiled the EXT100+120-25DA.D/L double-layer co-extrusion tandem line for PV cables. Adopting an integrated tandem structure combining main and auxiliary extruders, the equipment realizes one-step synchronous cladding of insulation and sheath for PV cables. Balancing high output, high precision and low energy consumption while supporting flexible production, it perfectly caters to large-scale manufacturing requirements of photovoltaic cables.

Key Takeaways

• A PV cable extrusion line is essential equipment for producing reliable photovoltaic cables used in solar energy systems.

• Tandem double-layer extrusion technology allows insulation and sheath layers to be produced simultaneously, reducing production time and material waste.

• The EXT100+120-25DA.D/L PV tandem extruder improves production efficiency by more than 40% compared with traditional production methods.

• Advanced PLC control, online monitoring, and automatic safety systems improve production stability and reduce operator dependence.

• High-speed solar cable manufacturing equipment helps cable manufacturers meet growing global demand for photovoltaic products.

What Is a PV Cable Extrusion Line?

A PV cable extrusion line is an automated manufacturing system used to produce photovoltaic cables for solar power generation applications.

During the extrusion process, polymer materials are heated, melted, and continuously applied around electrical conductors to form insulation and protective sheath layers. These layers protect cables from environmental factors such as:

• Ultraviolet radiation

• Extreme temperatures

• Moisture exposure

• Mechanical stress

• Long-term outdoor aging

Because PV cables are expected to operate reliably for decades, manufacturers require extrusion equipment that can provide:

• Stable production speed

• Accurate cable dimensions

• Uniform insulation thickness

• Excellent material processing capability

• Reliable quality inspection

A complete photovoltaic cable production line generally includes:

Compared with conventional extrusion equipment, modern PV cable extrusion machines focus on higher efficiency, better precision, and smarter operation.

Why Do PV Cable Manufacturers Need Advanced Extrusion Equipment?

Growing Global Demand for Photovoltaic Cables

The continuous expansion of solar energy projects is driving strong demand for PV cables.

In 2026, China’s photovoltaic installation market continues to grow rapidly, including:

• Large-scale desert and Gobi solar bases

• Commercial and industrial rooftop PV systems

• Residential solar power applications

The annual market size of PV cables is expected to exceed RMB 20 billion, with continued growth of more than 15%.

This market expansion requires cable manufacturers to increase production capacity while maintaining strict quality standards.

Traditional single-layer extrusion equipment is increasingly unable to satisfy modern PV cable manufacturing requirements.

Higher Quality Standards for Export PV Cables

With renewable energy projects expanding in Europe, Southeast Asia, the Middle East, and other regions, export-oriented PV cables require:

• Better weather resistance

• Higher dimensional accuracy

• Lower eccentricity

• Stronger aging resistance

Ordinary extrusion equipment often struggles to maintain consistent quality during high-speed production.

Therefore, advanced solar cable extrusion machines with precise control systems are becoming essential for manufacturers targeting international markets.

EXT100+120-25DA.D/L PV Tandem Extruder Production Line Overview

The EXT100+120-25DA.D/L PV Tandem Extruder Production Line developed by Jiangsu Handing Cable Equipment is designed specifically for high-speed photovoltaic cable manufacturing.

The equipment adopts a synchronous double extrusion structure that integrates a main extruder and auxiliary extruder into one production system.

The main advantages of this design include:

• One-step insulation and sheath forming

• Reduced secondary processing

• Higher production efficiency

• Lower material loss

• Improved cable consistency

Unlike traditional production methods requiring two separate extrusion processes, the tandem extrusion system completes double-layer cable forming continuously.

Core Technical Parameters of EXT100+120-25DA.D/L PV Cable Extrusion Line

The equipment supports different photovoltaic cable specifications and enables manufacturers to achieve both high-volume production and flexible order management.

How Does Tandem Double Layer Extrusion Improve PV Cable Production?

Traditional PV cable manufacturing usually requires:

• Insulation extrusion

• Intermediate cooling

• Cable handling

• Secondary sheath extrusion

This process creates several challenges:

• Longer production cycles

• Higher labor requirements

• Increased energy consumption

• More opportunities for surface damage

• Higher material waste

The tandem extrusion technology used in the EXT100+120-25DA.D/L production line solves these problems by combining insulation and sheath extrusion into a single continuous process.

Five Core Advantages of EXT100+120-25DA.D/L PV Tandem Extrusion Line

The rapid development of the solar energy industry requires PV cable manufacturers to improve production efficiency, reduce operating costs, and maintain consistent product quality. The EXT100+120-25DA.D/L PV Tandem Extruder Production Line addresses these challenges through advanced tandem extrusion technology, intelligent control systems, and energy-efficient design.

1. Synchronous Double-Layer Extrusion Improves Production Efficiency and Reduces Cost

One of the biggest advantages of this PV cable extrusion line is its integrated tandem extrusion structure.

Traditional PV cable manufacturing normally requires two separate production processes:

• First extrusion for insulation layer;

• Second extrusion for outer sheath layer.

During the intermediate transfer process, manufacturers may face:

• Additional labor costs;

• Longer production cycles;

• Higher material handling risks;

• Potential surface damage to semi-finished cables.

The EXT100+120-25DA.D/L system combines a 100 main extruder and 120 auxiliary extruder to complete insulation and sheath extrusion simultaneously.

This advanced design provides significant improvements:

Higher Production Efficiency

The synchronous double-layer extrusion process increases overall production efficiency by more than 40% compared with conventional production methods.

Manufacturers can achieve:

• Higher daily output;

• Shorter production cycles;

• Improved equipment utilization.

Lower Material Loss

Because the production process eliminates repeated traction, preheating, and die threading procedures:

• Semi-finished product handling loss is reduced by approximately 90%;

• Raw material waste is reduced by 6%–10%.

Faster Product Changeover

The equipment supports rapid material and specification switching.

Production changeover time can be shortened to within 15 minutes, making it suitable for:

• Large-scale PV cable orders;

• Customized cable production;

• Flexible manufacturing schedules.

2. Wear-Resistant Extrusion System Ensures Long-Term Stable Production

Photovoltaic cable materials often contain special additives such as:

• Flame retardants;

• UV-resistant compounds;

• Low smoke zero halogen materials.

These materials can create higher requirements for extrusion equipment because they may increase abrasion during long-term operation.

To improve equipment durability, the EXT100+120-25DA.D/L PV cable extruder adopts an upgraded wear-resistant screw and barrel system.

Advanced Nitriding Treatment Technology

The screws and barrels undergo deep nitriding treatment for more than 100 hours.

Technical advantages include:

• Nitriding depth ≥0.6mm;

• High surface hardness;

• Improved wear resistance;

• Reduced material buildup.

This allows the extrusion system to maintain stable performance during continuous high-speed PV cable production.

European-Style Barrier Screw Design

The optimized barrier screw structure provides:

• Better material mixing;

• More uniform plasticization;

• Stable extrusion pressure;

• Smooth cable surface quality.

The finished PV cables achieve:

• Better appearance;

• Reduced surface defects;

• Improved weather resistance.

Stable Transmission System

The screw and gearbox adopt an involute spline connection structure.

This ensures:

• Stable rotation speed;

• Reduced mechanical vibration;

• Consistent cable dimensions during long production runs.

For manufacturers producing export-quality photovoltaic cables, this stability is essential.

3. Intelligent Digital Control Reduces Labor Requirements

Modern cable manufacturing is moving toward intelligent and automated production.

The EXT100+120-25DA.D/L solar cable manufacturing equipment integrates a complete intelligent control system to simplify operation and improve production reliability.

Siemens PLC Intelligent Control

The production line uses a Siemens PLC control system to achieve:

• Extrusion parameter management;

• Automatic process adjustment;

• Synchronized equipment operation;

• Real-time production monitoring.

Operators can manage:

• Extrusion speed;

• Temperature parameters;

• Traction system;

• Take-up and pay-off operation.

One-Click Process Parameter Management

The control system can store hundreds of PV cable production formulas.

Benefits include:

• Faster product switching;

• Reduced setup time;

• Lower dependence on experienced operators;

• More consistent production quality.

Online Monitoring and Fault Detection

The complete production line integrates:

• Online outer diameter monitoring;

• High-frequency spark testing;

• Wire-break detection;

• Vibration monitoring;

• Limit protection sensors.

When abnormal conditions occur, the system can automatically:

• Reduce speed;

• Stop operation;

• Display alarm information.

This helps prevent production losses and improves equipment safety.

MES System Integration Capability

The equipment supports connection with factory MES systems.

Manufacturers can monitor:

• Production output;

• Energy consumption;

• Product yield rate;

• Equipment operating status.

This enables data-driven factory management and supports smart manufacturing transformation.

4. Low-Energy Green Design Supports Sustainable Manufacturing

Energy efficiency has become an important consideration for modern cable factories.

The EXT100+120-25DA.D/L photovoltaic cable production line adopts multiple energy-saving technologies to reduce operating costs.

Independent Segmented Heating System

The extrusion system uses segmented heating control.

When the equipment enters standby mode, the system automatically reduces power consumption.

Advantages:

• Lower electricity usage;

• Improved energy efficiency;

• Reduced operating expenses.

High-Efficiency Variable Frequency Drives

The extruder, traction, take-up, and pay-off motors are equipped with high-efficiency variable frequency drives.

Compared with traditional fixed-frequency motors:

• Power consumption can be reduced by more than 20%;

• Motor operation becomes more stable;

• Equipment control becomes more precise.

Reduced Cooling and Heating Consumption

Because tandem extrusion completes insulation and sheath production in one pass:

• Repeated heating is eliminated;

• Cooling water consumption is reduced;

• Overall manufacturing energy consumption decreases.

This supports cable manufacturers pursuing:

• Green Factory certification;

• Low-carbon manufacturing;

• Sustainable production goals.

5. Complete Safety System Ensures Reliable Operation

Safety is a critical requirement for industrial production equipment.

The EXT100+120-25DA.D/L PV tandem extrusion line integrates comprehensive safety protection systems.

The equipment includes:

• Cylinder-driven safety doors;

• Safety door position detection;

• Emergency stop interlock;

• Wire-break protection;

• Limit protection devices;

• Vibration monitoring sensors.

When any abnormal safety condition occurs, the system automatically:

• Locks operation;

• Stops equipment movement;

• Prevents potential mechanical risks.

The complete safety design complies with industrial safety requirements and supports CE certification standards.

PV Cable Manufacturing Market Outlook: Why Are Tandem Extrusion Lines Becoming Essential?

The photovoltaic industry is entering a new stage of high-quality and intelligent manufacturing development.

As solar installations continue expanding globally, PV cable manufacturers need equipment that can provide:

• Higher output capacity;

• Better product consistency;

• Lower production costs;

• Stronger international competitiveness.

Traditional single-layer extrusion machines are gradually becoming insufficient because they cannot fully meet the requirements of modern PV cable production.

Advanced PV cable extrusion lines with tandem double extrusion technology are becoming the preferred solution for manufacturers upgrading their production capabilities.

How to Choose a PV Cable Extrusion Line Manufacturer?

Selecting the right PV cable extrusion line manufacturer is an important decision for cable factories.

Before purchasing equipment, manufacturers should consider several key factors.

1. Production Capacity and Equipment Performance

A reliable PV cable extruder should provide:

• Stable high-speed operation;

• Suitable output capacity;

• Support for multiple cable specifications.

Important technical indicators include:

• Maximum line speed;

• Extrusion output;

• Cable diameter range;

• Dimensional accuracy.

2. Extrusion Precision and Quality Control

High-quality photovoltaic cables require accurate production control.

Manufacturers should evaluate whether equipment provides:

• Online diameter measurement;

• Spark testing;

• Automatic parameter adjustment;

• Stable extrusion pressure control.

3. Intelligent Automation Level

Modern cable factories require equipment with:

• PLC control;

• Production data monitoring;

• Remote diagnosis;

• MES integration capability.

Higher automation reduces labor costs and improves production consistency.

4. Technical Support and After-Sales Service

A professional PV cable extrusion equipment supplier should provide:

• Equipment installation guidance;

• Operator training;

• Maintenance support;

• Production optimization solutions.

Frequently Asked Questions About PV Cable Extrusion Line

1. What is a PV cable extrusion line used for?

A PV cable extrusion line is used to manufacture photovoltaic cables by applying insulation and protective sheath layers around electrical conductors. It ensures cables have excellent electrical insulation, weather resistance, and durability for solar power applications.

2. What is the advantage of tandem extrusion technology?

Tandem extrusion technology allows insulation and sheath layers to be produced simultaneously in one continuous process. Compared with traditional separate extrusion methods, it improves efficiency, reduces material waste, and lowers production costs.

3. What materials can be processed by a PV cable extruder?

A modern PV cable extruder can process various photovoltaic cable materials, including:

• XLPE;

• LSHF materials;

• Weather-resistant PE;

• Flame-retardant compounds.

4. Why should manufacturers upgrade from traditional extrusion equipment?

Modern solar cable markets require faster production speed, higher dimensional accuracy, and better quality control. Advanced tandem extrusion lines help manufacturers increase competitiveness and meet domestic and international market requirements.

5. What is the production speed of the EXT100+120-25DA.D/L PV tandem extrusion line?

The EXT100+120-25DA.D/L production line supports continuous high-speed operation up to 350m/min while maintaining stable cable quality and dimensional accuracy.

About Jiangsu Handing Cable Equipment

Jiangsu Handing Cable Equipment specializes in the research, development, and manufacturing of advanced cable extrusion equipment.

With expertise in cable production technology, intelligent manufacturing systems, and customized extrusion solutions, the company provides reliable PV cable extrusion lines, cable manufacturing equipment, and complete production solutions for global cable manufacturers.

Through continuous innovation in extrusion technology, automation control, and energy-efficient design, Jiangsu Handing Cable Equipment helps cable companies improve production efficiency, enhance product quality, and achieve intelligent manufacturing upgrades.

Conclusion: Upgrade PV Cable Manufacturing with Advanced Tandem Extrusion Technology

The growth of renewable energy is creating new opportunities and challenges for photovoltaic cable manufacturers.

The EXT100+120-25DA.D/L PV Tandem Extruder Production Line provides a complete solution by combining:

• High-speed double-layer extrusion;

• Intelligent automation;

• High precision control;

• Energy-saving operation;

• Reliable safety protection.

By replacing traditional production methods with advanced tandem extrusion technology, manufacturers can achieve higher productivity, lower manufacturing costs, and stronger competitiveness in the global solar energy market.

For cable manufacturers planning production upgrades, the EXT100+120-25DA.D/L represents an efficient and future-oriented solution for large-scale photovoltaic cable manufacturing.