Electric Wire Factory Inside | Complete 3 Core Cable Manufacturing Process 2026

Episode Overview

• Process Visualization: This video provides a step-by-step visual documentation of the manufacturing process for heavy-duty electrical cables in a semi-industrial setting.
• Resourceful Engineering: It showcases how raw materials—specifically copper wire, steel armor, and PVC pellets—are transformed into finished multi-core cables using a combination of manual labor and mechanical extrusion.
• Manufacturing Stages: The narrative follows the production line from the initial insulation of individual wires to the stranding of multiple cores, and finally, the application of protective outer sheathing and armor.

Key Concepts

• Extrusion and Insulation: The fundamental process for coating wires involves feeding PVC pellets (blue or black) into a heated hopper. A screw mechanism melts the plastic and forces it through a die head, coating the copper wire passing through the center. This creates the primary insulation layer.
• Stranding and Cabling: To create a multi-core cable, individual insulated wires must be twisted together. The video demonstrates a rotating cage machine that holds multiple spools of wire, spinning them around a central axis to bind them into a single, cohesive bundle before the outer sheath is applied.
• Thermal Management in Manufacturing: Heat plays a critical role throughout the process. Open flames are used to preheat the extrusion dies to prevent clogging and ensure smooth plastic flow. conversely, water troughs are immediately used after extrusion to cool the hot plastic rapidly, setting its shape and preventing deformation.
• Armoring for Durability: For heavy-duty applications, cables require physical protection. The video illustrates the application of steel wires (armoring) around the inner bundle. This layer provides tensile strength and protects the internal conductors from crushing or rodent damage.

Quotes

• At 1:13 - "Plastic pellets being inspected by hand" - This moment visually demonstrates the raw material input stage, showing the specific type of blue PVC granules used for the initial insulation layer.
• At 12:50 - "The rotating cage stranding machine in operation" - This segment reveals the mechanical complexity required to twist multiple insulated wires into a single helical bundle without tangling them.
• At 15:00 - "Finished black cable being coiled" - This final shot encapsulates the result of the multi-stage process, showing the transition from raw materials to a market-ready electrical product.

Takeaways

• Implement Rapid Cooling Systems: When working with thermoplastics in manufacturing, ensure immediate access to water cooling troughs post-extrusion to maintain dimensional accuracy and structural integrity.
• Utilize Pre-heating for Extrusion Efficiency: Apply direct heat to metal dies and extruder heads before operation to prevent material blockages and ensure a consistent, smooth coating on the wire.
• Adopt Mechanical Stranding for Uniformity: To create reliable multi-core cables, use rotating stranding machinery rather than manual twisting to ensure consistent tension and helical pitch, which improves the cable's flexibility and durability.