First, bare copper wire is loaded into a dual cone payoff. The payoff guides the wire coming off, and a tensioner keeps the wire taut. The tensioner allows the wire’s diameter to be electronically measured before extrusion. Next, wire enters the crosshead of the extruder for insulation. Two layers of PVC are applied: the foundation (its thickness), then a thin coating of colored PVC.

Upon exiting the extruder, the insulated wire’s diameter is remeasured. This “hot diameter” is around 400-degrees Fahrenheit. “Before and after” extrusion measures how much PVC insulation was added. After travelling 45 feet in cold water, wire enters the capstan which pulls the wire. Once the wire comes off the capstan, it is dried — then its cold diameter is measured.

The cable enters a sparker, which tests for any jacket defects — one spark will stop the line. Next the cable winds through a tensioner-accumulator, then the take-up, which reels the insulated wire. The take-up has two sides. When one side fills up, it automatically shifts to the opposite reel. The operator then pulls the full reel off and put an empty reel on. The individual wires are ready to be bundled into three-conductor cable.

A reel of each color-coded wire is loaded into the Neutralizer. The wires are guided down a forcing cone where they converge. A rotating capstan controls the length of lay of the wires — that is the distance between the high point of one wire on one side to the high point of the same wire on the other side, which is controlled by a rotating capstan. Once the wires have been “bunched,” it continues to the cabler and reeled onto a drum.

The drums of cable are loaded into payoffs for the extrusion line to be extruded into a single PVC jacket. The conductors unreel onto an accumulator where reels can be changed out without stoppage. Next, a sparker checks every inch of cable ensuring no copper is exposed. If exposed, the line automatically shuts down and the exposed section is replaced.

Next the cable is layered in talcum powder. Talcum separates the cable and the outer jacket for easier stripping. Finally, the cables are extruded into a single outer jacket consisting of a colored outer layer while the thicker inside is white PVC. After extrusion the cable’s hot diameter is measured. After cooling, it reaches the wet capstan which sets the speed cable moves through the extruder — speeds vary based on real-time measurements. Too fast produces thinner insulation, and too slow makes cable thicker. Computerized adjustments are constantly made.

Cable is dried before cold measurements are taken. The manufacturer’s name and specifications are printed on the cable. Next an accumulator rolls the cable onto 3500-foot reels. Once a reel is changed out, the accumulator releases product and the cable is wound around a new reel, reducing the amount of product in the accumulator.

The cable reels are ready for shipping.