Description
Machine Application
PTFE cannot be processed like conventional thermoplastics such as PE or PVC. It retains extremely high viscosity above its melting point and therefore cannot be processed with an ordinary melt-extrusion system.
PTFE insulated wire is normally produced using fine-powder PTFE resin mixed with a suitable extrusion aid. A paste extrusion machine continuously applies the PTFE insulation around the conductor.
After extrusion, the insulation passes through lubricant-removal, drying and high-temperature sintering stages. These steps create a continuous and consolidated PTFE insulation layer.
For this reason, a complete PTFE wire extrusion line must coordinate extrusion, sintering, traction, accumulation and take-up speeds.
Single-Layer and Double-Layer PTFE Wire
The machine can be configured for single-layer or double-layer PTFE insulation.
A single-layer structure is suitable for standard PTFE insulated wire. Double-layer insulation can use different layer thicknesses, colors or material configurations according to the product design.
The production method is determined by the conductor diameter, insulation thickness, PTFE formulation and required line speed.
Complete Extrusion Line Configuration
A PTFE wire extrusion line can be configured with:
- Conductor pay-off unit
- Conductor guiding and tension control
- PTFE paste extrusion machine
- Custom extrusion tooling
- Lubricant-removal and drying system
- Continuous PTFE sintering furnace
- Cooling system
- Capstan unit
- Wire accumulator
- Shaft-type take-up system
- Electrical control and speed synchronization
- Optional online inspection equipment
The production line is not limited to one fixed configuration. Each section can be matched to the conductor diameter, insulation thickness, required speed, reel weight and available factory space.
Reference Technical Specifications
| Parameter | Reference Configuration |
|---|---|
| Insulation Structure | Single-layer or double-layer PTFE insulation |
| Accumulator Capacity | 30m |
| Reference Line Speed | 5-20 m/min |
| Capstan Power | 1.5kW, 2.5kW, 3.7kW or 5.5kW |
| Take-Up Type | Shaft-type take-up |
| Reel Options | PN400-630, PN500-630, PN500-800, PN630-1000 or PN800-1250 |
| Take-Up Power | 1.5-5.5kW |
| Extrusion Tooling | Customized for conductor and insulation dimensions |
| Line Layout | Customized to available factory space |
Actual production speed also depends on conductor dimensions, insulation thickness, PTFE resin formulation, extrusion pressure, drying time and the effective length of the sintering furnace.
Line Speed and Take-Up Configuration
| Reference Speed | Capstan Power | Reel Options | Take-Up Power |
|---|---|---|---|
| 20 m/min | 1.5kW | PN400-630 | 1.5kW |
| 12-15 m/min | 2.5kW | PN500-630 or PN500-800 | 2.2-3.7kW |
| 8 m/min | 3.7-5.5kW | PN630-1000 or PN800-1250 | 5.5kW |
| 5 m/min | 5.5kW | PN800-1250 | 5.5kW |
These values are provided for preliminary selection. The final capstan power, reel size and take-up power are determined according to wire weight, continuous operating time and production requirements.
Products and Application Fields
The PTFE wire extrusion machine can be used to produce:
- Single-layer PTFE insulated wire
- Double-layer PTFE insulated wire
- High-temperature equipment connection wire
- Aerospace and defense wiring insulation
- Electronic and electrical equipment wiring
- Semiconductor equipment connection wire
- Automotive and electromechanical wiring
- Insulated wiring for medical equipment
- Wire for metallurgical and petrochemical equipment
Final wire performance depends on the conductor, PTFE resin grade, insulation structure, processing conditions and applicable testing standard.
SUKO Project Experience
SUKO has accumulated experience from multiple PTFE wire extrusion equipment and complete production-line projects.
We can design the line around single-layer or double-layer insulation, conductor dimensions, insulation thickness, target speed, reel size and available factory layout.
Before delivery, the equipment can be assembled, commissioned and test-run according to the target product. Testing covers extrusion stability, sintering temperature, traction speed, accumulator control and take-up coordination.
The following video shows an actual SUKO PTFE Wire Extruder in operation:
Machine Selection and Customization
Different PTFE wire products require different extruders, tooling, sintering furnaces, capstan systems and take-up units.
Customers may provide an existing wire sample, product photograph, simple drawing or basic specification. When the complete specification is not yet available, SUKO can begin with the intended wire type and approximate dimensions and help develop the machine configuration.
Line speed, reel size, electrical standard, control method and production-line layout can all be adapted to the actual factory conditions.
Frequently Asked Questions
Can PTFE wire be produced with an ordinary plastic extruder?
Normally, no. PTFE retains extremely high viscosity above its melting point and cannot be processed like PE or PVC. PTFE wire insulation usually requires fine-powder resin, an extrusion aid and a paste extrusion process.
Does SUKO supply only the extrusion machine?
SUKO can supply the extrusion machine separately or provide a complete line with pay-off, extrusion, drying, sintering, cooling, capstan, accumulation, take-up and control systems.
Can the machine produce double-layer PTFE insulated wire?
Yes. The system can be configured according to the conductor size, thickness of each insulation layer, material, color and required production speed.
What production speed is available?
The current reference range is 5-20 m/min. Actual speed depends on the wire dimensions, insulation thickness, PTFE formulation, sintering process and complete line configuration.
Can different wire sizes be produced by changing the tooling?
Yes. Tooling can be designed for different conductor and finished insulation diameters. Extrusion pressure, temperature, capstan speed and sintering settings must also be adjusted when changing specifications.
Can the same machine process FEP or PFA wire?
PTFE normally uses paste extrusion, while FEP and PFA are melt-processable fluoropolymers. Their extrusion equipment and processing methods are different, so FEP or PFA projects require a separate equipment configuration.
Contact SUKO
Planning to produce PTFE insulated wire? Send us a product photograph, existing sample or simple description. Our team can discuss the suitable extrusion-machine or complete-line configuration with you.
Contact: https://ptfe-machinery.com/contact/
Phone / WhatsApp: +86 19975113419
