The production process of electrical wire and cable

The production process of electrical wire and cable typically involves the following steps:

1. Wire Drawing:

In this step, copper or aluminum rods are drawn through a series of dies to reduce their diameter and form wire of the desired size.
2. Stranding:

Multiple wires are combined to form a stranded conductor. This process increases flexibility and reduces electrical resistance.
3. Insulation Extrusion:

The stranded conductor is passed through an extruder, where a layer of insulating material (such as PVC, XLPE, or rubber) is applied to provide electrical insulation.
4. Shielding:

In certain cable applications, a metallic shield is applied over the insulation to protect against electromagnetic interference (EMI) or radio frequency interference (RFI).
5. Jacketing:

A protective outer layer, usually made of PVC, is applied to the cable to provide mechanical protection and resistance to environmental factors like moisture and sunlight.
6. Cabling:

Multiple insulated conductors or insulated pairs/triples are combined to form a cable core, which can be further twisted or laid up together.
7. Armoring (Optional):

In some applications where added mechanical protection is required, a layer of metal braid or tape may be added as an armor.
8. Testing:

Various tests are conducted on the finished cables to ensure compliance with performance and safety standards.
9. Packing and Delivery:

Once the cables pass the quality control tests, they are coiled, packed, and sent for delivery to the customers.

What’s the test process of wires and cables?

The testing process for wires and cables typically involves several steps.

Here is a general outline of the process:

1. Visual Inspection: The wires are visually inspected for any physical damage, such as cuts, abrasions, or deformities.

2. Dimensional Measurement: The dimensions of the wires, including their diameter or thickness, are measured to ensure they meet the specified requirements.

3. Electrical Testing: Different electrical tests are performed to verify the quality and performance of the wires. These tests may include:

– Insulation Resistance Test: Measures the resistance between the conductor and the insulation to ensure it is within acceptable limits.
– Dielectric Strength Test: Checks the ability of the insulation to withstand high electric voltages without breaking down.
– Conductor Resistance Test: Measures the resistance of the conductor to ensure it meets the specified requirements.
– Voltage withstand Test: Applies high voltage to the cable to assess its ability to withstand electrical stress without failure.

4. Mechanical Testing: Various mechanical tests are conducted to evaluate the strength and durability of the wires. These tests may include:

– Tensile Strength Test: Measures the maximum force the wire can withstand before breaking.
– Flexibility Test: Evaluates the wire’s ability to bend or twist without any damage.
– Abrasion Test: Assesses the wire’s resistance to wear and tear caused by repeated movement or rubbing.
– Impact Test: Determines the wire’s ability to withstand sudden impacts without damage.

5. Marking and Packaging: Once the wires pass all the required tests, they are marked with relevant information like manufacturer details, product specifications, and certifications. They are then packaged for distribution.

It’s important to note that the specific testing procedures may vary depending on the type of wire or cable being manufactured and the industry standards applicable in different regions or countries.

What’s the difference between silicone and teflon material ?

Silicone and teflon are two types of non-stick materials that are used in a variety of applications. Although they have similar properties, they are different in terms of composition and uses.

Silicone is a synthetic rubber-like material composed of silicon, oxygen, carbon, and hydrogen. It is flexible, heat-resistant, and waterproof, and can withstand temperatures ranging from -40°F to 500°F (-40°C to 260°C). Silicone is used in kitchenware such as baking mats, baking pans, and cooking utensils due to its non-stick properties and ability to withstand high temperatures.

On the other hand, Teflon is a brand name for a type of fluoropolymer comprised of molecules of carbon and fluorine. It is known for its excellent non-stick properties and is used as a coating on cooking appliances, non-stick cookware and bakeware, and even in medical applications due to its biocompatibility. Teflon can withstand high temperatures and is chemically inert, which means it doesn’t react with other substances.

In summary, while silicone is flexible and heat-resistant, teflon is known for its excellent non-stick properties and chemical inertness. Both materials are commonly used in cooking and baking applications.

What are the shielding materials of the cable?

Shielded cables have a layer of conductive material that surrounds the inner wires and helps to reduce electromagnetic interference (EMI) or radio frequency interference (RFI). The shielded material can be made up of various materials such as metal foils like aluminum or copper and braided metal wires made up of copper. The materials used to create the shield can vary based on the intended application for the cable. For example, in high EMI areas, multiple layers of shields may be used to provide additional protection.

The addition of a shield to a cable helps to reduce electromagnetic interference and improve the overall signal quality of the cable. The shield provides a barrier that helps to prevent external electrical noise from interfering with the signal that is being transmitted through the cable. The shield can be made of a variety of materials, such as copper or aluminum foil, braided wire, or a conductive polymer. The specific type of shield used will depend on the type of cable and the environment in which it will be used. Overall, adding a shield to a cable is an important step in ensuring reliable and high-quality signal transmission.

What’s the difference between bare copper, tinned copper, silver copper and nickel copper?

Bare copper is a pure form of copper that doesn’t have any kind of coating or plating applied to it. It is the most commonly used form of copper in electrical applications because it is a good conductor of electricity and is typically less expensive than other copper types.

Tinned copper is a copper wire that has been coated with a thin layer of tin. The tin helps to prevent the copper from corroding and also makes it easier to solder. Tinned copper is often used in marine environments because it is more resistant to corrosion than bare copper.

Silver copper is a copper wire that has been coated with a thin layer of silver. This type of copper wire is extremely conductive, making it ideal for applications where high conductivity is required. However, it is typically more expensive than bare or tinned copper wire.

Nickel copper is a copper wire that has been coated with a thin layer of nickel. The nickel layer provides the wire with a number of benefits, including increased strength and resistance to corrosion. Nickel copper wire is often used in applications where high strength and durability are required, such as in the aerospace industry.

In summary, the main differences between these types of copper are the presence of a coating or plating and the specific properties that are conferred by that coating. Each type of copper has different advantages and disadvantages depending on the intended use.

What is the difference between FEP and PTFE material?

Both FEP and PTFE are fluoropolymer materials with similar properties, but they do have some differences.

FEP stands for fluorinated ethylene propylene and is a copolymer of hexafluoropropylene and tetrafluoroethylene. It has a lower melting point (about 260°C) than PTFE, and is also more transparent and flexible. FEP is often used as a non-stick coating for cookware and bakeware, as well as in electrical applications, due to its excellent insulation properties.

On the other hand, PTFE stands for polytetrafluoroethylene and is made up of only tetrafluoroethylene monomers. It is known for its exceptional chemical resistance, low coefficient of friction, and high temperature resistance (up to 327°C). PTFE is commonly used in non-stick coatings for cookware, as well as in manufacturing of seals, gaskets, and bearings.

In summary, while both FEP and PTFE are fluoropolymers and share some similarities, their different melting points, transparency, and properties make them more suitable for specific applications.

How to select the right wire and cable?

Selecting the right wire and cable depends on the specific application and requirements.

Here are some factors to consider:

1. Voltage rating: The wire or cable must be rated to handle the voltage of the circuit it will be used in.

2. Current rating: The wire or cable must be able to handle the amount of current that will flow through it without overheating.

3. Type of insulation: The insulation material used on the wire or cable should be compatible with the environment in which it will operate, such as high or low temperatures, chemicals, and moisture.

4. Gauge or size: The size of the wire or cable should be appropriate for the current it will carry and the length of the circuit.

5. Conductor material: The conductor material should be suitable for the application. Copper is commonly used for most applications, but aluminum is sometimes used for larger cables or where weight is a concern.

6. Shielding: Shielding may be necessary to protect against interference from other electrical devices.

7. Environmental factors: Consider the environment in which the wire or cable will be used. Will it be exposed to harsh weather conditions? Will it be used indoors or outdoors? Will it be exposed to vibration or mechanical stress?

It’s important to consult with a qualified engineer or electrician when selecting wire and cable to ensure that you are selecting the most appropriate materials for your specific application.

How do South African companies import wire and cable from China?

1. The company need import license and USD account.
2. Choose the right wire and cable from Shanghai Shoayer Wire and Cable Co.,Ltd.


3. Finished production, Shoayer will entrust freight forwarder to declare and shipment it by sea or by air.
4. Entrust a freight forwarder to clear customs and consign, when the wire and cable arrived.

But, how to choose the right wire and cable? Shoayer will tell you in detail at next article.

Accepted customized

  1. Super thin PTFE wire

Conductor: 270/0.05 tinner plated copper

Insulation: PTFE transparent

O.D.: 2.0mm

2. 200mm² PVC cable

Conductor: 40/2.52mm Stranded Aluminum wire

Insulation: PVC Red/White/Black/Blue/Yellow/Green

O.D:22.5±1mm