Peroxide Cross-Linking: Molten XLPE is mixed with organic peroxides, then extruded over the conductor and heated to 200°C–220°C. The peroxides decompose, releasing free radicals that initiate cross-linking. This method is cost-effective and suitable for large-scale production.

Silane Cross-Linking: XLPE is grafted with silane monomers, then extruded and exposed to moisture (via water or steam). The silane groups react with water to form cross-links, ideal for small-batch or Custom Cables.

Radiation Cross-Linking: High-energy electrons (from an electron beam) are used to break polymer chains, which then rejoin to form cross-links. This method produces the most uniform cross-linking but is more expensive.

Thermal Stability: XLPE maintains its insulation properties at temperatures up to 90°C (continuous operation) and can withstand short-term overloads up to 130°C for 8 hours. This makes it suitable for environments with high ambient temperatures, such as industrial boiler rooms or outdoor installations in tropical climates.

Low Dielectric Loss: With a dielectric loss factor (tan δ) of less than 0.001 at 50Hz, XLPE minimizes energy loss during power transmission. For a 1km cable run carrying 200A, this translates to annual energy savings of approximately 500kWh compared to rubber-Insulated Cables.

Moisture Resistance: The dense cross-linked structure prevents water ingress, even when the cable is submerged in water for extended periods. This eliminates the risk of “water trees”—microscopic channels that form in uncross-linked PE and cause insulation breakdown over time.

Chemical Resistance: XLPE is resistant to oils, greases, acids (pH 4–10), and alkalis, making it suitable for use in chemical plants, refineries, and automotive factories where exposure to harsh substances is common.

PVC Sheaths: The standard option for most indoor and outdoor applications, PVC sheaths are formulated with additives to enhance performance:

PE Sheaths: Used in specialized applications requiring enhanced flexibility or low-temperature performance:

Aluminium Tape Shielding: A 0.1mm thick aluminium tape is wrapped around the stranded cores to provide electromagnetic interference (EMI) shielding, preventing signal disruption in sensitive environments (e.g., hospitals or laboratories).

Steel Wire Armouring: Galvanized steel wires (1.2mm diameter) are helically wrapped around the sheath to resist impact and compression. This variant, designated YJV22, has an outer diameter of 50mm–53mm and a weight of 5.5kg per meter, suitable for direct burial in construction sites or road crossings.

High Ampacity: The 95mm² core size handles the high current demands of equipment like 200kW compressors, 150kW conveyor systems, and 100kW welding machines.

Chemical Resistance: XLPE insulation and PVC/PE sheaths resist oils, coolants, and solvents used in automotive, aerospace, and electronics manufacturing.

Mechanical Durability: Steel wire armoured (YJV22) variants withstand impacts from forklifts, pallets, and heavy tools, reducing the risk of cable damage and unplanned downtime.

Compact Design: The 42mm–45mm outer diameter fits into narrow conduit systems within walls and ceilings, maximizing space efficiency in high-rise buildings where ductwork and piping compete for space.

Flame Retardancy: PVC sheaths meet IEC 60332-3, preventing fire spread between floors—essential for buildings with large occupant loads.

Moisture Resistance: XLPE insulation’s water impermeability makes it suitable for basement electrical rooms and rooftop HVAC units, where humidity levels are high.

Cost-Effectiveness: Aluminium core variants are 30% cheaper than copper, making them ideal for large-scale residential projects where budget is a priority.

UV Stability: PE sheaths with carbon black additives resist sun damage in outdoor installations, such as street lighting poles.

Underground Durability: YJV22 variants can be buried directly in soil without additional protection, reducing installation costs compared to concrete encasement.

Low Dielectric Loss: XLPE’s low energy loss ensures maximum power transfer from solar panels or wind turbines to the grid, improving the project’s overall efficiency.

Weather Resistance: PE sheaths withstand extreme temperatures (-40°C to 80°C) and UV radiation, making them suitable for outdoor renewable installations.

Corrosion Resistance: Aluminium conductors (with a zinc coating) resist corrosion in coastal wind farms, where saltwater spray is a concern.

Sheath Extrusion: For PVC sheaths, the stranded cores are fed into a PVC extrusion line, where molten PVC (heated to 160°C–180°C) is extruded over the cores to form a sheath (2.5mm–3.0mm thick). The PVC is mixed with additives (carbon black for UV stability, flame retardants) before extrusion. For PE sheaths, the extrusion temperature is lower (140°C–160°C) to prevent PE degradation. The extruded sheath is cooled in a water bath to solidify.

Reinforcement Application: If the cable requires armouring, Steel Tape or wire is applied before sheath extrusion. For steel tape armouring, a tape-wrapping machine applies galvanized steel tape around the stranded cores with a 15%–20% overlap. For steel wire armouring, a wire-stranding machine helically winds steel wires around the cores at a lay length of 10–15 times the cable’s diameter. FRP reinforcement is applied as a coating, using a extrusion process similar to the sheath.

Electrical Tests:

Mechanical Tests:

Environmental Tests:

Wooden Reels: Constructed from high-density plywood (18mm–22mm thick) or pine, wooden reels are lightweight and cost-effective. The reel consists of a central hub (diameter 400mm–600mm) and two flanges (diameter 800mm–1200mm) to prevent the cable from slipping off. The wood is treated with a water-resistant coating (e.g., polyurethane) to protect against moisture during outdoor storage. Each wooden reel can hold up to 500m of the cable (approximately 1400kg for aluminium-core variants or 2100kg for copper-core variants) and is reinforced with steel brackets at the hub to withstand lifting forces.

Steel Reels: For heavy-duty use or repeated reuse (e.g., construction companies that frequently order cables), steel reels are preferred. Made from galvanized steel (2mm–3mm thick), these reels are corrosion-resistant and can support up to 1000m of cable (3000kg+). The flanges are reinforced with ribs to prevent bending, and the hub is fitted with a 50mm–100mm diameter hole to accommodate lifting rods or reel stands. Steel reels are also stackable, saving storage space in warehouses.

The cable is wound tightly onto the reel with uniform tension to prevent tangling or kinking.

The outer layer of the cable is wrapped with 2 layers of stretch film (15μm thick polyethylene) to shield against dust, dirt, and light moisture.

A layer of corrugated cardboard is placed between the cable and the reel flanges to prevent abrasion during transit.

A label is affixed to the reel flange, containing the product details, reel length, weight, and handling instructions (e.g., “Do Not Drop,” “Store in Dry Area”).

The cartons are made from double-walled corrugated board (E-flute or B-flute) with a bursting strength of 150kPa, ensuring they can withstand stacking and minor impacts.

The cable is coiled loosely inside the carton to prevent kinking, with foam padding (20mm thick) placed at the top and bottom to absorb shocks.

For lengths over 10m, the cable is wrapped around a cardboard spool (diameter 150mm) to maintain its shape.

The carton is sealed with reinforced packing tape (50mm wide) and labeled with the same product details as reel-packaged cables, plus a “Fragile” sticker to alert handlers.

Truck Type: Flatbed trucks or enclosed trucks are used, depending on weather conditions. Enclosed trucks are recommended for rainy or snowy weather to protect the cable from moisture, while flatbed trucks are used for large reel shipments (over 500kg) that require crane loading.

Securing the Cargo: Reels are placed on wooden pallets (1200mm×1000mm) to distribute weight evenly and prevent damage to the truck bed. Steel reels are secured with heavy-duty ratchet straps (50mm wide, 5t load capacity) attached to the truck’s side rails, with rubber padding between the straps and the reel flanges to avoid scratches. Wooden reels are additionally wrapped in shrink film to protect against moisture during transit. For carton-packaged cables, the cartons are stacked on pallets (max 5 layers) and wrapped with stretch film to prevent shifting.

Transit Monitoring: GPS tracking devices are installed on trucks carrying high-value or large-volume shipments, allowing both the manufacturer and customer to monitor the shipment’s location in real time. The logistics provider also assigns a dedicated coordinator to each shipment, who provides daily updates on transit progress and addresses any delays (e.g., traffic, weather) promptly.

Container Selection: Standard 20ft or 40ft dry containers are used, depending on the shipment volume. A 20ft container can hold up to 12 steel reels (500m each) or 20 wooden reels (500m each), while a 40ft container can double these quantities. For carton-packaged cables, a 20ft container can accommodate up to 500 cartons (10m each). The containers are inspected for leaks, damage, or contamination before loading to ensure the cable remains dry and clean.

Loading and Securing: Reels are loaded into containers using forklifts or cranes, with wooden dunnage (200mm×100mm×500mm) placed between reels to prevent movement during transit. The reels are also secured to the container’s floor with steel bolts (M16) to withstand the ship’s motion (pitching, rolling). Cartons are stacked on pallets and secured with angle brackets to prevent tipping.

Moisture Protection: Desiccant bags (1kg each) are placed inside the container (1 bag per 10m³ of space) to absorb moisture and prevent condensation, which could damage the cable’s insulation or sheath. The container is also lined with a vapor barrier film to further reduce moisture ingress.

Customs and Documentation: The manufacturer works with a customs broker to prepare all required documentation, including the commercial invoice, packing list, certificate of origin, and certificate of compliance. These documents are submitted to customs authorities 3–5 days before the container’s departure to ensure smooth clearance. For shipments to countries with strict import regulations (e.g., the EU, USA), additional certifications (e.g., CE marking, UL listing) are provided.

Cargo Preparation: Reels are disassembled (if possible) to reduce size, and the cable is coiled into smaller bundles (max 20m per bundle) wrapped in bubble wrap. Carton-packaged cables are placed in special air cargo containers (UL-approved) to meet airline safety standards. The total weight of each shipment is limited to 1000kg per flight, as per most cargo airlines’ restrictions.

Transit Time: Air shipments typically take 2–5 days for international deliveries, compared to 2–4 weeks for sea shipments. The manufacturer coordinates with the airline to prioritize the shipment, ensuring it is loaded onto the next available flight.

Cost Considerations: Air transportation is 5–10 times more expensive than sea transportation, so it is only recommended for urgent needs. The manufacturer provides a detailed cost breakdown to the customer before confirming the shipment, including air freight, handling fees, and customs clearance costs.

Order Verification: The team reviews the order details (product specifications, quantity, delivery address, payment terms) within 24 hours of receipt. If there are any discrepancies (e.g., incorrect core material, missing delivery instructions), the team contacts the customer to resolve them before proceeding.

Inventory Check: The team checks the warehouse inventory to confirm the availability of the ordered cable. For standard variants (aluminium core, PVC sheath), inventory is usually available within 1–2 days. For custom variants (copper core, PE sheath, armouring), the team coordinates with the production department to schedule manufacturing, with a lead time of 7–10 days.

Production Scheduling (for Custom Orders): The production department creates a detailed schedule, including conductor drawing, insulation extrusion, and testing, and shares it with the customer. The customer is updated weekly on production progress, with photos or videos of the cable being manufactured upon request.

Shipment details (tracking number, carrier name, transportation mode).

Expected delivery date (with a 1–2 day buffer to account for unforeseen delays).

Contact information for the logistics coordinator and carrier.

Digital copies of all shipping documents (invoice, packing list, certificate of compliance).

Inspection: The customer is encouraged to inspect the cable’s packaging for damage (e.g., broken reels, torn cartons) before signing the delivery receipt. If damage is found, the customer should take photos of the damage and notify the manufacturer and carrier within 24 hours.

Unloading Assistance: For large reel shipments, the carrier provides a crane or forklift to unload the reels at the customer’s site, free of charge. The manufacturer’s technical team can also be dispatched to assist with unloading, upon request.

Acceptance Confirmation: After inspecting the cable, the customer signs a delivery acceptance form, which is sent back to the manufacturer. If the customer is satisfied with the shipment, the order is marked as complete. If there are any issues (e.g., incorrect specifications, damaged cable), the manufacturer works with the customer to resolve them (e.g., replacement, repair) within 3–5 days.

Online Request: The manufacturer’s website has a dedicated sample request form, where customers can select the cable variant (conductor material, sheath type, length), provide their contact and delivery details, and specify any special requirements (e.g., additional testing). The form is processed within 48 hours.

Direct Contact: Customers can also request samples via email, phone, or video call with the sales team. The sales team provides guidance on selecting the right sample variant based on the customer’s application (e.g., recommending a PE sheath for cold climates) and confirms the request within 24 hours.

Sample Availability: Standard variants (aluminium core, PVC sheath) are available as samples within 3–5 days. Custom variants (copper core, armoured) require 7–10 days to manufacture, with the customer notified of the expected sample delivery date.

Length: Samples are typically 1m–5m long, which is sufficient for testing electrical performance, flexibility, and sheath durability. Longer samples (10m–20m) are available upon request, for customers who want to test the cable in real-world installations (e.g., connecting to a motor).

Labeling: Each sample is labeled with the product specifications (core size, conductor material, sheath type, rated voltage), manufacturing date, and batch number. This allows customers to trace the sample back to the production batch, ensuring consistency with bulk orders.

Packaging: Samples are packaged in small, branded cartons (250mm×150mm×100mm) with foam padding to prevent damage during transit. The carton also includes a sample information sheet, which details the cable’s specifications, test results (insulation resistance, conductor resistance), and installation guidelines.

Testing Guide: A detailed testing guide is included with each sample, outlining step-by-step instructions for conducting common tests (e.g., insulation resistance test using a megohmmeter, flexibility test by bending the cable around a mandrel). The guide also includes safety precautions (e.g., wearing gloves when handling the cable, using a calibrated test instrument).

Technical Assistance: Customers can contact the manufacturer’s technical support team (via phone, email, or video call) for guidance on testing. The technical team can also review test results and provide recommendations (e.g., if the insulation resistance is lower than expected, the team may suggest checking the test environment for moisture).

Custom Testing: For customers with specific testing requirements (e.g., flame retardancy test per IEC 60332-1), the manufacturer can conduct the test in its in-house laboratory and provide a detailed test report. This service is available for an additional fee, which is deducted from the customer’s subsequent bulk order if they decide to purchase.

Installation Manual: A detailed installation manual is provided with each order, containing:

On-Site Installation Support: For large-scale or complex installations (e.g., industrial plants, power distribution networks), the manufacturer can send a team of certified technicians to the customer’s site to supervise the installation. The technicians provide real-time guidance to the customer’s installation team, ensuring compliance with the installation manual and industry standards. This service is available for an additional fee, which is based on the number of technicians and the duration of the on-site visit.

Installation Training: The manufacturer offers training courses for the customer’s installation team, either at the manufacturer’s facility or the customer’s site. The courses cover topics such as cable handling, termination techniques, and testing, and include hands-on practice with the 4 Core 95mm² YJV XLPE Insulated Power Cable. The training is led by experienced engineers, and participants receive a certification upon completion.

Covered Defects: The warranty covers defects such as:

Warranty Claim Process: To file a warranty claim, the customer must:

Exclusions: The warranty does not cover damage caused by:

Maintenance Guidelines: The manufacturer sends a maintenance guide to the customer 6 months after delivery, outlining recommended maintenance tasks (e.g., inspecting the cable for sheath damage, testing insulation resistance annually) and schedules. The guide also includes tips for extending the cable’s lifespan (e.g., keeping the cable away from heat sources, protecting it from UV radiation).

Technical Support Hotline: A dedicated technical support hotline is available 24/7, staffed by engineers with 5+ years of experience in Electrical Cables. Customers can call the hotline for assistance with maintenance issues (e.g., interpreting insulation resistance test results), troubleshooting (e.g., identifying the cause of a power outage related to the cable), or general questions (e.g., compatibility with other electrical equipment).

Preventive Maintenance Services: For customers with large cable installations (e.g., industrial plants with 10km+ of cable), the manufacturer offers preventive maintenance services. A team of technicians visits the customer’s site annually to inspect the cable, test its performance (insulation resistance, conductor resistance), and identify potential issues (e.g., early signs of sheath degradation). The team provides a detailed maintenance report, including recommendations for repairs or replacements if needed.