Wire and Cable Production Line and Factory Setup

A wire and cable production line is a complete industrial system designed to draw copper or aluminium wire, anneal, strand, insulate and package electrical wires and cables under controlled process conditions. The line produces power cables, building wires and industrial cables depending on the selected insulation and armouring equipment.

From an industrial perspective, wire and cable manufacturing is important because it combines precise wire drawing, controlled annealing, accurate stranding and reliable extrusion of PVC or XLPE insulation to achieve consistent conductivity, dielectric strength and mechanical performance. The process relies on a defined sequence of unit operations that must be correctly engineered, sized and integrated.

Primary materials typically include copper or aluminium rods, PVC or XLPE compounds and packaging materials. The core machinery set consists of wire-drawing machines (10–30 m/s), annealing furnaces (500–700 °C), stranding machines (500–1500 rpm), insulation extruders (20–120 mm diameter) and coiling equipment.

The Industrial Department supports investors who want to establish a new wire and cable plant as well as existing operators who need repair, overhaul, capacity expansion or automation of their current lines. Projects can start from an empty site or from an operating facility that requires technical upgrading.

Whether the goal is a green-field turnkey cable plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The wire and cable line is engineered as an integrated process system covering wire drawing, annealing, stranding, insulation extrusion, optional armouring and coiling. Design capacity is determined during the engineering phase and can typically range from 1 to 10 tonnes per day.

Main machinery groups include wire-drawing machines, annealing furnaces, stranding machines, insulation extruders and coilers. Supporting infrastructure covers electrical power, steam or gas and process water.

Manpower requirements depend on the degree of automation. Quality control covers conductor diameter, insulation thickness, dielectric strength and package integrity.

Technical Specifications

Specification	Description
Product	Electrical wires and cables (PVC/XLPE insulated)
Production Capacity	1–10 tonnes per day
Required Area	1000–3000 m²
Electrical Power	380 V three-phase, 200–500 kW
Steam / Gas	100–300 kg steam per hour
Water Consumption	10–30 m³/day
Manpower	10–25 persons per shift
Main Machines	Wire-drawing machine, annealing furnace, stranding machine, insulation extruder, coiler

All figures are indicative.

Products

Building wires, power cables and industrial cables with PVC or XLPE insulation in various cross-sections.

Raw Materials for Wire and Cable Factory

Primary materials are copper or aluminium rods, PVC or XLPE compounds and packaging materials.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of copper/aluminium and insulation compounds required by wire and cable plants.

Registering an order for raw materials for the factory Wire and Cable
Sahi Rasa Supply Chain Department

Support is available for projects in Iran, Iraq, Kurdistan Region, Afghanistan and other regional markets.

Manufacturing Process

1. Wire Drawing – Copper or aluminium is drawn to the required diameter (10–30 m/s).
2. Annealing – Wire is softened at 500–700 °C.
3. Stranding – Conductors are twisted (500–1500 rpm).
4. Insulation Extrusion – PVC or XLPE is applied (20–120 mm diameter).
5. Coiling and Packaging – Finished cable is coiled and packed.

Machinery & Equipment

• Wire-Drawing Machine – Reduces rod diameter (10–30 m/s). Position: first stage. Importance: conductor size accuracy. Quality impact: uneven drawing causes resistance variation. Maintenance: dies, drums and lubrication systems. Sahi Rasa support covers design, installation, repair and spare parts.
• Annealing Furnace – Softens the wire (500–700 °C). Position: after drawing. Importance: ductility and conductivity. Quality impact: incorrect temperature affects mechanical properties. Maintenance: heaters and atmosphere control.
• Stranding Machine – Twists conductors (500–1500 rpm). Position: after annealing. Importance: flexibility and current capacity. Quality impact: incomplete stranding causes stiffness. Maintenance: cages, bows and drives.
• Insulation Extruder and Coiler – Applies insulation and coils the cable. Position: end of line. Importance: dielectric strength and packaging. Quality impact: incomplete insulation causes electrical failure. Maintenance: screws, dies and coiling systems.

Factory Layout & Building Requirements

Typical areas include rod storage, drawing, annealing, stranding, extrusion, coiling, quality control, utilities and staff facilities. Exact area is determined during engineering.

Utilities

• Electricity: 380 V three-phase, 200–500 kW
• Steam/Gas: 100–300 kg/h
• Water: 10–30 m³/day

Turnkey Factory Setup

An investor can start from an empty site. The project can be accompanied through feasibility, engineering, design, machinery, installation, commissioning, training and commercial production.

EPC & PMC

Projects can be executed under EPC or PMC approaches within defined contracts.

Machinery Repair

Existing wire and cable lines can request inspection, repair and spare-parts support for drawing machines, annealers, stranders and extruders.

Machinery Overhaul & Refurbishment

Older equipment can be overhauled and control systems upgraded.

Capacity Expansion

Capacity can be increased by upgrading drawing or extrusion stages.

Industrial Automation

PLC control of speed, temperature and coiling is typical.

Supply Chain

The Supply Chain Department supports copper, aluminium and insulation compound supply.

Packaging

Coils, reels and labelling are integrated according to market requirements.

Branding & Product Development

Support for product development and technical documentation is available when required.

Market & Country Sections

Services are available in Iran, Iraq, Kurdistan Region, Afghanistan and other listed regional markets.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment
Factory Design	Layout and process design
Machinery Design / Manufacturing	Equipment specification and supply
Procurement	Sourcing of machinery and materials
Installation & Commissioning	Start-up and testing
Automation	PLC and process control
Raw Material Supply	Via Supply Chain Department
Repair / Overhaul	Restoration of existing equipment
Capacity Expansion	Throughput increases
Staff Training	Operational training

Why Sahi Rasa

Integrated process engineering, machinery, installation and training provide a clear path from concept to operating production line.

From Empty Land to Production

Typical sequence from feasibility through commercial production.

Who Should Contact Sahi Rasa?

• Investors planning a new wire and cable plant
• Existing owners needing repair, overhaul or expansion
• Industrial buyers requiring machinery or materials

Final CTA

Contact the Industrial Department for factory setup, machinery, repair, overhaul or raw-material coordination.

Registering an order for raw materials for the factory Wire and Cable

FAQ

1. What capacity can be designed?
   Typically 1–10 tonnes per day.
2. Which main machines are required?
   Wire-drawing machine, annealing furnace, stranding machine, insulation extruder and coiler.
3. How much space is needed?
   Approximately 1000–3000 m².
4. Can existing lines be repaired?
   Yes.
5. Are turnkey projects available?
   Yes under defined contracts.
6. Are services available in Iraq and Afghanistan?
   Yes.
7. Can copper and compounds be supplied?
   Yes via the Supply Chain Department.
8. Is installation included?
   It can be included according to the package.
9. What about automation?
   PLC and process control can be provided.
10. How is capacity expanded?
    By upgrading drawing or extrusion stages.