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It is an open secret that fire-resistant magnesium hydroxide and aluminum hydroxide are generally utilized in the manufacturing of halogen-free flame retardant cable through FRP coating lines methodology. A majority of cable producers in the industry make use of this methodology to manufacture secured and flame retardant wires and cables. Halogen-free flame retardant materials offer unmatched protection and insulation properties yet they are so combustible that they need to be made fire-retardant as per the requirements.
The plastic compounds in the past released hazardous substances
The first compounds for cable insulation were developed in the1980s and since then their use in the global cable industry has been increasing by leaps and bounds. Flame retardation properties in the wires and cables have also captured the attention of wires and cable insulation solutions providers because of the growing concerns of people’s safety from fire in homes, offices, and business establishments. The plastic used in the past for cable manufacturing released hazardous substances and was responsible for frequent major fire outbreaks.
Typical applications of HFFR cable compounds
In Europe, the legal guidelines call for the utilization of HFFR compounds in FRP coating lines supported by capstans for public facilities as well as establishments that include mega structures, tunnels, and transportation. In the times to come, these guidelines are expected to be followed in countries like India, China, and the Middle East.
In plants and engineering developments, the use of HFFR compounds for complex and security-sensitive establishments, for example, power stations, modern labs, and drug plants, server stations, and so on has already become a mainstream practice. To meet the demanding prerequisites for fire-resistant properties, it is important to add 50-70 % of the fitting fillers. For certain applications, as much as 80% is required.
Formulations are consequently preferred with PE-copolymers, which empower higher filler ingestion. Coupling or potentially cross-connecting frameworks are incorporated to achieve the required mechanical and application-specific properties. The HFFR wire and cable made through FRP coating lines supported by capstans can be considered a great innovation in the field of compounding frameworks.
Compounding requirements
Compounding requirements for an effective and efficient FRP coating lines incorporate, most importantly, dispersive and distributive blending at low liquefied temperatures (< 190°C for ATH) to handle the added substances and high substance of fire retardants as indicated by industry guidelines. Thanks to its operating principles, a large number of mixing processes, at moderate and uniform shear rates, capacitates the best mixing efficiency for the high quality at maximum throughput.
Concluding Remarks
Supermac Industries (India) Limited has been a technological leader in the manufacturing of extrusion machines since 1974. Today, the company is meeting the needs of numerous industries in the cables sector such as power, optical fiber, house wiring control cables, and medical lines. The company boasts of having a rich product portfolio that includes FRP coating lines, insulation line for building wires/automotive wires, insulation line and sheathing line for power cables, triple extrusion line for insulation of silane-xlpe cables up to 33 kV, dry cure CCV lines for medium voltage cables, extruders, cross-head, caterpillar and capstans.
