Screw Vacuum System for Cable Insulation & Sheath Quality
Puyan Machinery customized a screw vacuum system for a cable manufacturer to ensure quality in insulation layer treatment and sheath extrusion molding. In the cable manufacturing industry, processes such as gas removal from cross-linked insulation layers, sheath extrusion molding, and finished cable drying all have strict requirements for a vacuum environment. Recently, Shanghai Puyan Machinery Equipment Co., Ltd. successfully delivered a customized screw vacuum system to a cable manufacturer, effectively solving the customer's problems of insufficient vacuum level and poor system stability during production.
Project Background: High Requirements for Vacuum Systems in Cable Production
The customer is primarily engaged in the R&D and production of medium and high-voltage power cables and special cables. During the cable manufacturing process, processes such as bubble removal from cross-linked insulation layers, negative pressure forming during sheath extrusion, and vacuum drying of finished cables all require a continuously stable negative pressure environment. The stability of the vacuum level directly affects the insulation performance, service life, and finished product yield of the cables.
The customer previously used multiple small vacuum pumps for decentralized air supply, which presented the following problems: after parallel connection of multiple units, the vacuum level fluctuated significantly, affecting the quality of insulation layer treatment; the decentralized layout occupied a large amount of workshop space and made maintenance management inconvenient; and the lack of a centralized control system resulted in high energy consumption. The customer explicitly requested a highly reliable, intelligently controlled screw vacuum system capable of providing centralized and stable negative pressure supply to multiple pieces of equipment in the workshop.
Puyan Solution: Puyan Screw Vacuum Pump PVG080 + 100L Stainless Steel Buffer Tank + Puyan PLC Control Panel
After conducting an on-site survey, the Puyan Machinery technical team customized the following configuration based on the air usage characteristics of cable production:
- Core Vacuum Source: Puyan Screw Vacuum Pump PVG080. This pump features a non-contact twin-screw rotor design, with a pumping speed of 80 m³/h, an ultimate vacuum of 50 Pa, and a power rating of 2.2 kW. It operates smoothly with low noise, making it suitable for long-term continuous operation in a cable workshop. The screw pump has no easily worn vanes, offers a long maintenance interval, and significantly reduces the maintenance burden on the equipment department.
- Buffering System: 100L stainless steel buffer tank. It effectively smooths out vacuum fluctuations, ensuring stable pressure at all usage points. The stainless steel material provides corrosion resistance and high cleanliness, making it suitable for environments with volatile gases that may be present in cable production.
- Control System: Puyan PLC control panel. Utilizing a programmable logic controller, it enables one-button start/stop of the system, automatic control based on upper and lower pressure limits, fault alarms, and real-time monitoring of operating status. The panel is equipped with a remote communication interface for integration with the customer's factory-level monitoring system.
The complete system underwent program testing and airtightness testing before leaving the factory. On-site installation only required connection to the main pipeline and power supply, significantly reducing commissioning time.
Project Results: Stable Vacuum, Intelligent Control, Improved Production Line Efficiency
Since the screw vacuum system was put into operation, the customer's production workshop has reported significant improvements:
- Stable and Reliable Vacuum: In key processes such as cross-linked insulation layer treatment and sheath extrusion, the system vacuum level has remained consistently within the set range, with no quality issues caused by vacuum fluctuations.
- Efficient and Convenient Centralized Air Supply: One system serves multiple workstations, replacing the previous multiple decentralized small vacuum pumps. Workshop space utilization has significantly improved, and the piping layout is now more organized and standardized.
- Intelligent Automatic Operation: By setting upper and lower pressure limits on the PLC, the system automatically starts and stops based on the total air demand of the main pipeline, avoiding idle energy consumption. Overall power consumption is significantly lower compared to the original decentralized air supply method.
- Easy Maintenance: The screw vacuum pump has no wear parts such as vanes. Combined with the stainless steel buffer tank's ability to trap impurities, the maintenance interval has been greatly extended, requiring minimal intervention from the equipment department.
The customer's production manager commented: "After installing Puyan's screw vacuum system, the workshop vacuum has never fluctuated. The PLC control is simple to operate, and the operating data is clear at a glance. For future new production lines, we will continue to choose Puyan's vacuum systems."
Why Choose Puyan Machinery's Screw Vacuum System?
Puyan Machinery specializes in vacuum pumps and custom vacuum systems. Our core strengths lie in on-demand customization (providing non-standard designs based on air volume, vacuum level, media, etc.), our own brand with reliable quality, and rapid response (providing solutions within 24 hours). Besides cable manufacturing, this screw vacuum system is also widely used in semiconductor, lithium battery vacuum drying, food and pharmaceutical packaging, electronic component handling, shipbuilding, and other industries. If your plant faces issues such as insufficient vacuum, system instability, or the need for a new system, please contact Puyan Machinery for a customized solution.