Application · Cable Compound
XLPE Cable Compound: Silane Grafting Two-Step Process
Silane cross-linked PE must be grafted first and catalysed later. Do both in one pass and the compound starts cross-linking inside the barrel — which is a one-day cleaning job, not a quality deviation. A reference xlpe cable compound page from Kerke.
XLPE Cable Compound — workshop photo 1, Kerke workshop, Nanjing
XLPE Cable Compound — workshop photo 2, Kerke workshop, Nanjing
XLPE Cable Compound — workshop photo 3, Kerke workshop, Nanjing
XLPE Cable Compound — workshop photo 4, Kerke workshop, Nanjing
XLPE Cable Compound — workshop photo 5, Kerke workshop, Nanjing
XLPE Cable Compound — workshop photo 6, Kerke workshop, NanjingQuick answer
XLPE (cross-linked polyethylene) cable compound is produced on a two-stage line that keeps melt temperature below the cross-linking initiation point, with L/D 32–40 in the first stage and air-cooled pelletizing. Output 200–1,500 kg/h. Silane or peroxide systems each need a different temperature ceiling.
Workshop photos and a running video — shot on our own lines, not stock images.
What sets the limit
PE, silane, peroxide and antioxidant are metered and compounded below the initiation temperature, then pelletized with air cooling and packed in moisture-barrier bags.
| Parameter | Value / range |
|---|---|
| Systems | Silane cross-linked PE / peroxide XLPE |
| Temperature ceiling | Below cross-linking initiation (typ. 150–170 °C) |
| Pelletizing | Air-cooled hot die-face or strand |
| Output (reference) | 200–1,500 kg/h |
| Model | KTE/SE-75/180, KTE/SE-95/200 |
Output figures are measured on the reference material stated above. Filler grade, bulk density and moisture move output by ±15% — that is why every quotation we issue is tied to a trial report.
Process flow, step by step
- FeedingLoss-in-weight dosing of polymer and filler; side feeder or liquid injection where the formulation needs it.
- Melting and dispersingScrew geometry with 45°/90° kneading blocks; barrel profile set by the polymer.
- DevolatilizationVacuum vent at −0.06 to −0.09 MPa removes moisture and volatiles before the die.
- Pressure build-upThrottle or discharge section stabilises die pressure; a melt pump where gauge control matters.
- Pelletizing and packingAir-cooled hot die-face or strand; then centrifugal dryer, vibrating screen and bagging.
Equipment configuration
| Stage | Equipment | Why this choice |
|---|---|---|
| Main machine | Two-Stage Extruder KTE/SE | Architecture follows the filling level and the mixing duty, not the required tonnage. |
| Screw geometry | Building-block elements, W6Mo5Cr4V2, bimetallic liner | Wear package for abrasive filler; mixing blocks only where dispersion demands them. |
| Feeding | Loss-in-weight feeder, side feeder where needed | Recipe accuracy: ±0.5% short term on the weighed component. |
| Pelletizing | Pelletizing system | Chosen by polymer and filler ceiling — water contact is the deciding column. |
| Downstream | Centrifugal dryer, vibrating screen, bagging | Fines below 2% and moisture below the specification of your downstream process. |
Output by model
| Configuration | Stage 1 (twin screw) | Stage 2 (single screw) | Output (kg/h) | Typical product |
|---|---|---|---|---|
| KTE-50B / SE-120 | 50.5 mm | 120 mm | 300–500 | Colour / filler masterbatch |
| KTE-65B / SE-150 | 62.4 mm | 150 mm | 500–800 | Filler masterbatch 85%, PVC |
| KTE-75B / SE-180 | 71 mm | 180 mm | 700–1,200 | High filler 88–90%, HFFR |
| KTE-95B / SE-200 | 93 mm | 200 mm | 1,000–2,000 | High filler, cable compound |
Three mistakes that cost the most
1. A 10 °C overshoot starts cross-linking inside the barrel: gel particles block the cable di
A 10 °C overshoot starts cross-linking inside the barrel: gel particles block the cable die downstream.
2. Moisture pickup in packing ruins the shelf life of silane XLPE.
Moisture pickup in packing ruins the shelf life of silane XLPE.
3. No melt filtration before the cable head
No melt filtration before the cable head — a single gel particle scraps a whole reel; specify a fine screen changer and trend the die pressure.
FAQ
Can you guarantee no pre-cross-linking?
We guarantee temperature control (±2 °C) and residence time; actual pre-cure is verified by a gel-content test on your formulation in a trial.
Strand or hot die-face for XLPE?
Both are used; hot die-face with air cooling is more common for cable compound because pellet surface quality matters.
What output can you guarantee for this application?
The reference band is 200–1,500 kg/h, measured on the stated material. We quote a guaranteed figure only after a trial on your own material, because filler grade, bulk density and moisture move output by ±15%.
Can we run our material before ordering?
Yes — send 25–50 kg. We return pellets, a running video and a report with temperatures, screw speed, feeder settings and output per hour. The trial is free; you cover the freight.
What is the delivery time?
30–45 working days for standard configurations, 45–70 for custom screw geometry and ODM work. Voltage and frequency are built for the destination country.
Where these numbers come from
Parameters are taken from the Kerke product parameter table and the product master data sheet, and cross-checked against commissioning records for lines in the same application. Formulations and temperature windows are typical industry values, not a recommendation for your specific compound — every figure marked reference must be confirmed on a material trial before it becomes a contractual number.
Reviewed by the Kerke process team, Nanjing. Page updated 6 November 2026.
Send 25–50 kg and we run it on our lab extruder: pellets, running video and a capacity report back in 3–7 days.
XLPE cable compound — the short version
Note on xlpe cable compound: the numbers above are reference ranges from Kerke's own trial runs, not catalogue promises. Screw geometry, wear package and pelletizing method are set on the trial bench first, so the output you compare is the output you get. If your grade is not in the tables, send it — the closest configuration is usually a change of screw set, not a different machine.
Related on this site: Machine range: KTE-50B to 135D · Pelletizing methods compared · quotation and free trial · Wikipedia: Masterbatch