WIRE & CABLE EXTRUSION SYSTEMS

The combined technologies of Davis-Standard and Merritt Davis Electric have created a powerful force

in the wire and cable marketplace. We manufacture complete wire and cable systems for building and

communication wire, construction wire, coaxial cable, automotive wire, high temperature wire, and

specialty wire applications. Systems are available with a wide range of extruders, payoffs and tension

brakes, take-ups, and auxiliary equipment including cooling troughs, capstans, caterpillars, and accumulator

systems. Laboratory equipment, customized feedscrews, and control systems are also available.

Communication SystemsCOAXIAL CABLEAccurately controlled foaming systems are manufactured for both chemical and gas injected operations. Upstream and downstream equipment that improves structural return loss (SRL) and consistently provides coaxial cable core is also available. Post-production sheathing lines and fluoropolymer components are also available for high temperature dielectrics.

COPPER TELEPHONECopper telephone lines with speeds up to 2500 mpm are available for solid, foam, and foam skin dielectrics. The complete line of fluoropolymer extruders, crossheads, flyer payoffs, wire drawing, and annealing equipment can be customized to meet specific requirements and integrated into a complete system. Plenum communication cables and sheathing lines with or without jelly-filling taping and armoring are also available.

LEVELS LINESPrecision data wire lines are built for the production of both high and low temperature Category 5 singles. The use of precision bearings and gear reducers, along with dynamic balancing of rotating sheaves and capstan wheels, promotes superior SRL performance in the finished product. Increased drive stability, high accuracy temperature control, and tension control on these lines allows for the production of extremely high performance data cables for Level 5 and above. Davis-Standard also manufactures lines for jacketing these precision products.

High Speed Primary Line

Power Cable SystemsRADIANT HEAT GAS CURE SYSTEMThis system provides a fast and economical dry cure for thermoset insulations, particularly XLPE. By utilizing nitrogen as the curing media, the presence of moisture is eliminated during the critical curing process. A patented by-product removal system that removes contaminates and increases the efficiency of the radiant curing system by circulating the nitrogen continuously is optionally available.

• Cure system components are manufactured to quality specifications for pressure vessels and fabricated stainless steel.

• Complete system includes an in-tube, no-contact sag control, variable water level and pump controls, primary seal and lead wire seals.

• The heated tube is divided into separately controlled heat zones, which are independently adjustable to 842°F (450°C).

• Heating elements are calrods uniquely designed for extended life.• Each zone is equipped with blowers to circulate air through the chamber around the calrods for fast

cooling during shutdown.• System can be utilized as a gas/water system for low and medium voltage, gas/gas system for

high and extra-high voltage, and as a steam/super-steam system for rubber products.• Can be retrofitted to an existing continuous vulcanization line.

STEAM CURE SYSTEMThese systems are best suited for minimum investment cost, and for extrusion compounds not formulated for high temperature curing. A variety of configurations of steam CV processing are available. Steam boilers provide fast pressure rise in the cure tube at start-up.

• Steam cure systems provide broad flexibility in operation.• Water level controls permit accurate control of steam-to-water ratios for optimum cure conditions on

every cable construction.• This equipment processes rubber, XLPE, and regular thermoplastic polyethylene without changing a

major piece of equipment. • Power cables from utility through transmission voltage may be produced over a very broad

speed range.

84-inch Belt Wrap Capstan

Specialty Wire SystemsBUILDING WIREHigh output lines are engineered for insulating single cores and jacketing multi-conductor insulated constructions. These lines provide continuous operation with packaging of the product in coils, on reels, or on stem packs. Building wire lines can extrude PVC from powder or pellets, and can co-extrude multi-layer constructions such as nylon over PVC. They use fixed or adjustable center crossheads. A continuous supply of either solid or stranded conductor may be fed into the line.

AUTOMOTIVE WIREDavis-Standard lines are used for primary automotive wire for signals, pressure gauges, lights, lighters, alarms, and controls. From 19 to 24 gauge, these lines are engineered to provide reliable performance and high quality wire.

SPECIALTY WIRE CAPABILITIESCustom lines can be designed to meet specialty wire requirements including equipment for fiber optic cable lines, CATV cable lines, high temperature wire lines, and silicone rubber lines. Bring us your requirements and we’ll engineer a solution.

Extruders, Feedscrews, and ControlsEXTRUDERSDavis-Standard is recognized worldwide for quality extruders. Single screw extruders are available in sizes from 3/4-inch to 15-inch (19mm to 380mm) diameters with L/D ratios from 10:1 to 42:1. This includes grooved feed throats, vented barrel, tiltable, and tandem specialty single screw machines. Vertical extruders are available in 3/4-inch to 3-inch (19mm to 76mm) diameters. Davis-Standard also offers twin screw conical and parallel extruders for RPVC processing and compounding applications.

FEEDSCREWSOur DSB®, DSBM™, and DSBM-T™ feedscrews are superior in design, construction, and versatility. Output is maximized and melt temperature is controlled, while thoroughly homogenizing the polymer melt. Each feedscrew is manufactured on the basis of individual customer parameters encompassing output rate, melt temperature, pressure requirements, output consistency of extruder stability, melt homogeneity, and melt quality.

CONTROLSDavis-Standard is one of the leaders in advanced process control systems for the plastics and rubber industries. The EPIC III™ color touch-screen operator interface and supervisory control system features patented dual-thermocouple control, responsive closed loop line control with an “operator friendly” graphical interface featuring pictorial control screens, trending, SPC/SQC networking, and other data acquisition capabilities.

We also offer our mid-range MESA controls and DS-eTPC (Davis-Standard - Extrusion Touch Panel Control) systems for less demanding applications. Both provide a touch panel solution to replace discrete temperature controllers, temperature indicators, pressure indicators, pressure controllers, drive operators, and drive indicators. The DS-eTPC includes a 12.1-inch color touch screen with built in PLC processor, subpanel mounted multi-loop temperature control, and PLC I/O modules required for the system.

All systems are custom engineered in-house for system reliability.

Wire Handling EquipmentCAPSTANSWe custom engineer multi-pass, linear, and belt wrap type capstans for the full range of wire and cable applications. Capstans include single wheel belt wrap type from 24 to 84 inches (610 to 2134mm) in diameter.

Linear CatTrak capstans with gripping lengths to 80 inches (2032mm) are available with 2,500 pounds (1134 kg) of traction force. Dual wheel multi-pass wet capstans are available from 12 to 32 inches (305 to 812mm) in diameter with lengths up to 60 feet (18 meters) for increased cooling capacity in both flood and spray configurations. Over/under arrangements can be provided in either flood or spray depending on application. Speeds up to 9,500 fpm (2,896 mpm) are available based on product range and requirements.

PAYOFF AND TAKE-UP SYSTEMSWe supply a complete range of payoff and take-up systems designed to handle products as small as 40 awg soft copper and as large as jacketed cable to 6 inches (150mm) in diameter. The payoff product offering includes Flyer Type, both single and dual, in sizes from 24 to 50 inches (600 to 1270mm) with accompanying lift trucks and tension brake assemblies.

Single reel payoffs, both motorized and drag type, and single reel take-ups in various configurations including roll-thru, retracting arm shaftless and shaft type, with ranges from 12- to 144-inch (300 to 3650mm) flange diameters with weight capacities to 60,000 pounds. For precise control, a complete line of oscillating designs are available. Dual reel fully automatic take-ups range in size from 6 to 50 inches (150 to 1270mm) and include both shaft type for speeds to 5,000 fpm (1,524 mpm) and shaftless designs running at speeds to 9,500 fpm (2,896 mpm).

SPOOLERSSpoolers are offered for reel sizes from 6 to 16 inches (150 to 400mm) in both semi-automatic and in the fully automatic Turret 4000 Automatic Series. Shaft type and shaftless single and dual reel machines are available for both in-line or rewind applications.

SP-16R Spooler

AKO 96 Take-up

Pora 72 Payoff

DC-24 WCT Mutipass Cooling Capstan

24/7 Customer Service/Aftermarket Services We have service technicians available 24 hours a day, seven days a week, to handle parts inquiries and emergency service needs. Parts shipments, if in stock, can be shipped within one day. We maintain complete mechanical and spare parts inventories ranging from feedscrews and barrels to thermocouples and motors. On-site service by a technician is also available. For parts and service call +800-480-8105.

Get to Know Us Davis-Standard has set the standard in wire and cable equipment and systems. We hope you will take the time to get to know us. Our capabilities go far beyond our equipment. They extend to our professional training experts, laboratory personnel, design engineers, and hands-on field engineers who will work with you every step of the way.

PS-24HSA High-Speed Shaftless Take-up with Reel Handling

DRT-24 Dual Take-up

500H-60 Accumulator

Inventoried electrical and mechanical spare parts.

Davis-Standard Business AreasAftermarket Services

Blow Molding Systems

Blown Film Systems

Cast Film Systems

Compounding Systems

Elastomer Systems

Extrusion Coating and Laminating Systems

Fiber Systems

Foam Systems

Laboratory Equipment and Specialty Systems

Liquid Coating and Laminating Systems

Pelletizing Systems

Pipe, Profile and Tubing Systems

Process Control Systems

Recycle/Reclaim Systems

Sheet Systems

Twin Screw Systems

Unwinding and Winding Systems

Wire and Cable Systems

46 North First StreetFulton, NY 13069-1297 USATel: +315-598-7121Fax: +315-593-0396www.bc-egan.com

Room 1007, Jing An China Tower1701 Beijing (W) RoadShanghai 200042 P.R. CHINA Tel: +86-21-5150 1908 Fax: +86-21-5150 1906www.davis-standard.com

#1 Extrusion Drive | Pawcatuck, CT 06379-2313 USA | Tel: +860-599-1010 | Fax: +860-599-6258 | www.davis-standard.com

Unit 33 Hainge RoadTividale, Oldbury, West MidlandsB69 2NY UNITED KINGDOM Tel: +44-121-522-0030 Fax: +44-121-522-0031 www.davis-standard.com

Mettmanner Strasse 51D-40675 Erkrath/DüsseldorfGERMANYTel: +49-211-2404-0Fax: +49-211-2404-281www.er-we-pa.de

36 South Adamsville RoadSomerville, NJ 08876-0671 USATel: +908-722-6000Fax: +908-722-6444www.bc-egan.com

© 2007 Davis-Standard, LLC. All Rights Reserved. JWRP5K1007