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Product Description
The PP Cable Protection Flexible Spiral Strip Hose Production Line is a fully integrated extrusion system engineered by Chenxing Machinery for the continuous, automated manufacturing of spiral-wound cable protection conduit. Covering finished pipe diameters from Φ12 mm to 180 mm, this turnkey line converts PP, PE, or PVC raw material into finished spiral hose rolls in a single uninterrupted process — from pellet feeding to finished coil winding.
Spiral wrap cable sleeving is a high-growth product category driven by expanding infrastructure for industrial automation, electric vehicles, renewable energy, and structured cabling. As a complete pipe extrusion line solution, this system combines a single-screw extruder, rotary forming machine, haul-off unit, cooling tank, meter counter, and automatic winder into one compact, operator-friendly footprint.
The line's core extruder — the SJ series — features a 38CrMoAlA alloy steel screw with nitriding treatment for exceptional wear and corrosion resistance, paired with a cast-aluminum heater and fan-cooling system managed by PID electronic temperature controllers (±1 °C accuracy). Six extruder models span throughputs from 19.5 kg/h to 40 kg/h, covering every production scale from pilot runs to full-scale industrial output.
For manufacturers seeking diversification into the cable management sector, this line offers a proven path to producing high-margin spiral protection hose for automotive wiring harnesses, building electrical conduits, industrial robotics, consumer electronics, and more — all on a single, reliable platform backed by Chenxing Machinery's engineering expertise.
The spiral hose line integrates six core processing units in sequence. Each unit is independently optimized yet synchronized for continuous, unmanned production. Below is the full layout.
At the heart of the line, the SJ series single-screw extruder plasticizes PP/PE/PVC granules and meters them through a custom-profiled die head. The screw and barrel are machined from 38CrMoAlA alloy steel with deep nitriding treatment, delivering hardness exceeding HV 900 on the surface layer — this directly translates to years of reliable service even when processing abrasive, filled, or recycled-grade materials.
Heating is provided by cast-aluminum band heaters arranged in multiple independently controlled zones along the barrel. Each zone is monitored and driven by a PID electronic temperature controller that maintains setpoint accuracy within ±1 °C, eliminating hot spots that cause polymer degradation and cold zones that produce unmelt. Forced-air cooling fans between zones enable rapid heat dissipation during start-up, grade changes, and shutdown.
Six extruder configurations are available (see Technical Specifications below), with screw diameters of 30, 45, and 50 mm and L/D ratios from 20:1 to 28:1. For start-up material blending or recycling edge trim, the line can be paired with a high-speed mixer and, if regrind is to be re-introduced, a plastic crusher.
After exiting the die, the molten tube enters the rotary forming machine — the defining component that transforms a plain extruded tube into a spiral-wound strip profile. A rotating mandrel and synchronized take-off system create the helical wrap geometry, controlling both pitch (helix spacing) and wall thickness with mechanical precision.
The forming head is adjustable across the full 12–180 mm diameter range, and pitch settings can be dialed in to achieve the target coverage ratio and flexibility for the end product. Tooling changes between different diameters are designed to be straightforward, minimizing downtime for product changeovers.
Downstream of the rotary former, four units complete the line:
Caterpillar haul-off machine: A belt-type caterpillar haul-off provides constant, slip-free pulling at a precisely regulated speed. Tension control is critical for spiral hose — too high and the helix deforms; too low and the product wanders. The pipe haul-off unit maintains uniform line speed synchronized with the extruder output.
Circulating water cooling tank: A stainless-steel trough with spray bars and immersion sections rapidly sets the spiral profile. Circulating water keeps the cooling medium at a stable temperature, and the tank length can be configured based on line speed to ensure the hose is fully set before entering the haul-off.
Meter counter: A contact-type or non-contact length measurement device records the exact linear meters produced, feeding data to the winder for automatic roll-change at pre-set lengths. This is essential for packaging accuracy and customer order fulfillment.
Automatic winder / pipe coiler: The finished spiral hose is automatically wound onto reels or into coils. The double-station pipe winding machine option allows non-stop production — when one station reaches its target length, the line automatically transfers to the second station while the operator removes the finished coil.
For facilities that also produce rigid PVC conduit requiring socket ends, a pipe belling machine is available as an optional add-on module downstream, and a dust-free pipe cutter can be integrated for precise length cutting.
Six extruder configurations cover the full range of production volumes. All models feature 38CrMoAlA nitrided screws, cast-aluminum heaters with fan cooling, and PID temperature control with ±1 °C accuracy. Center height is standardized at 1000 mm across all models for a uniform operator working plane.
| Model | Screw Dia. (mm) | L/D Ratio | Rotational Speed (r/min) | Center Height (mm) | Capacity (kg/h) | Drive Power (kW) |
|---|---|---|---|---|---|---|
| SJ-30/25CY | 30 | 25:1 | 10–160 | 1000 | 19.5 | 2.2 / 3 |
| SJ-45/20HY | 45 | 20:1 | 10–90 | 1000 | 22.5 | 5.5 |
| SJ-45/25CY | 45 | 25:1 | 16–160 | 1000 | 35 | 7.5 / 11 |
| SJ-45/28CY | 45 | 28:1 | 16–160 | 1000 | 40 | 7.5 / 11 |
| SJ-45/25HY | 45 | 25:1 | 16–160 | 1000 | 35 | 11 |
| SJ-50/25HY | 50 | 25:1 | 16–160 | 1000 | 40 | 11 / 15 |
Model nomenclature: "SJ" denotes Screw Extruder; the first number is screw diameter in mm; the second number is the L/D ratio; "CY" denotes a lower-speed configuration suitable for thick-wall and high-viscosity formulations; "HY" denotes a higher-speed configuration optimized for high-throughput continuous production. Dual drive power values indicate primary motor + auxiliary motor configurations for different operating conditions.
Selecting the right model depends on your target output (kg/h), the specific polymer and filler system, and the average pipe diameter you intend to produce. Contact our engineering team for a detailed recommendation based on your production plan.
The screw and barrel are the most wear-critical components in any extrusion line. We machine both from 38CrMoAlA premium alloy steel and apply a deep nitriding treatment that produces a surface hardness exceeding HV 900. This provides exceptional resistance to abrasive wear from filled polymers and corrosive attack from PVC decomposition byproducts. Compared to conventional nitrided 40Cr or untreated screws, the 38CrMoAlA pair delivers 2–3× longer service life, reducing downtime and replacement costs.
Each heating zone is governed by an independent PID loop with dedicated thermocouple feedback. The cast-aluminum heaters provide uniform radial heat distribution, while forced-air cooling fans enable rapid temperature pullback. The result is setpoint accuracy within ±1 °C across all zones. Tight thermal control directly translates to consistent melt viscosity, uniform wall thickness, and elimination of burn marks or unmelt defects — issues that plague lines using simpler on/off thermostats.
The rotary forming machine is purpose-designed for spiral hose geometry. Unlike general-purpose downstream equipment adapted for spirals, this unit controls both helix pitch and wall thickness through synchronized mechanical cam and mandrel profiles. The result is a consistent, repeatable spiral pattern across the full production run — critical for products where coverage ratio, flexibility, and appearance directly affect market value.
A single line can process polypropylene (PP), polyethylene (PE), and polyvinyl chloride (PVC) with appropriate temperature profile and screw configuration settings. This flexibility allows manufacturers to serve multiple market segments — rigid PP for automotive, flexible PE for consumer products, and flame-retardant PVC for building applications — without investing in separate dedicated lines. Custom formulations for flame retardancy (UL94 V-0), UV stabilization, anti-static properties, and color masterbatch are fully supported.
The top-tier models (SJ-45/28CY, SJ-50/25HY) deliver 40 kg/h nominal output, enabling annual production volumes that justify the investment for mid-to-large-scale manufacturers. Even the entry-level SJ-30/25CY at 19.5 kg/h provides sufficient throughput for specialized, high-value product runs. The L/D ratio options (20:1 to 28:1) let you balance throughput against melt quality depending on your material requirements.
All six units — extruder, rotary former, haul-off, cooling tank, meter counter, and winder — are electrically and mechanically synchronized. A central control panel provides start/stop, speed adjustment, temperature monitoring, and alarm management for the entire line. Once parameters are set, the line runs continuously with minimal operator intervention. Material feeding can be automated via a screw feeder, reducing manual loading labor.
With tooling changes, the line covers the entire Φ12 mm to Φ180 mm finished product range. Small-diameter hose (12–32 mm) serves electronics and data cable markets; medium diameters (32–80 mm) address automotive and industrial cabling; large diameters (80–180 mm) target heavy industrial and infrastructure applications. This breadth of coverage lets a single production line address multiple customer verticals.
Every aspect of the final product can be tailored: color (any RAL or Pantone match), flame retardancy (up to UL94 V-0), hardness (Shore A/D adjustable via formulation), UV resistance (for outdoor applications), anti-static (for electronics), and spiral pitch (for specific coverage or flexibility requirements). This customization capability is a key differentiator for manufacturers competing on value-added products rather than commodity pricing.
The entire six-unit line is designed for a compact, linear floor layout that maximizes production floor utilization. Equipment-to-equipment connections are pre-engineered, reducing on-site installation time. The standardized 1000 mm center height across all extruder models and downstream units ensures ergonomic operator access and simplifies maintenance.
The line integrates seamlessly with upstream and downstream plant equipment. For material preparation: a high-speed mixer for blending, a screw feeder for automated hopper loading, and a plastic crusher for reclaiming edge trim. For cooling: an SML air-cooled chiller provides closed-loop process water. For scrap reprocessing: a plastic pelletizer or PVC hot-cutting pelletizing line converts regrind back into reusable pellets.
The manufacturing process is a fully continuous sequence from raw material to finished coil. Understanding each step helps operators optimize quality and troubleshoot production issues.
Step 1 — Material Feeding: PP, PE, or PVC granules (optionally pre-blended with color masterbatch, UV stabilizers, or flame retardants in a high-speed mixer) are loaded into the extruder hopper. An automatic screw feeder can maintain a consistent hopper level for uninterrupted running.
Step 2 — Plasticizing & Extrusion: Material enters the single-screw barrel, where it is progressively heated, compressed, and melted through the feed, compression, and metering zones. The 38CrMoAlA nitrided screw, running inside the temperature-controlled barrel, delivers a homogeneous melt to the die head. PID controllers in each zone maintain ±1 °C accuracy, ensuring the melt exits the die at uniform temperature and viscosity.
Step 3 — Rotary Spiral Forming: The molten tube enters the rotary forming machine immediately after the die. A rotating mandrel and forming head impart the helical spiral geometry, controlling the pitch, wall thickness, and coverage ratio. This step is the defining process for spiral hose — the mechanical precision of the rotary former directly determines product quality and consistency.
Step 4 — Cooling & Solidification: The formed spiral hose passes through a circulating water cooling tank. Spray bars and immersion zones rapidly lower the polymer temperature below its crystallization or glass-transition point, locking in the spiral geometry and preventing post-extrusion deformation. Water temperature is stabilized by an industrial chiller in closed-loop configuration.
Step 5 — Haul-off & Tension Control: A caterpillar haul-off machine grips the cooled hose and pulls it at a precisely controlled linear speed, synchronized with the extruder output rate. Constant tension is maintained to avoid stretching (which would thin the wall) or slack (which would cause wandering and pitch variation).
Step 6 — Length Metering: The meter counter records the accumulated length with high precision, providing real-time production data and triggering the winder to change reels at pre-set length thresholds.
Step 7 — Automatic Winding: The finished spiral hose is wound onto reels or into coils by the pipe coiler. The double-station configuration enables continuous production — while one coil finishes, the line automatically transfers to the second station without stopping.
For manufacturers who also produce rigid plastic conduit, this line can be positioned upstream of a pipe belling machine and pipe cutting machine for socket-forming and precision cutting of rigid pipes on the same factory floor.
Spiral-wound cable protection hose manufactured on this line serves a remarkably broad range of industries. The product's combination of flexibility, abrasion resistance, and ease of installation makes it the preferred cable management solution across diverse sectors.
In factory automation cells, robot arms, CNC machines, and conveyor systems, hundreds of cables and hoses must be bundled, protected, and routed through dynamic motion paths. Spiral wrap sleeving provides abrasion protection, organization, and flexibility — allowing cables to bend and flex without kinking or chafing against metal structures. The 12–180 mm range covers everything from a single sensor cable to a large multi-line umbilical.
Electrical codes in many regions require mechanical protection for cables run through walls, ceilings, and underground conduits. PP spiral hose serves as a lightweight, corrosion-proof alternative to metal conduit for indoor and outdoor building wiring. Its flexibility simplifies installation through complex routing paths, and its insulation properties eliminate grounding concerns associated with metal conduit.
Modern vehicles — particularly electric and hybrid platforms — contain kilometers of wiring. Spiral wrap sleeving protects wire harnesses in engine compartments, door panels, battery packs, and underbody routing from heat, vibration, moisture, and abrasion. Flame-retardant grades (UL94 V-0) are specified for high-voltage EV battery cabling. The ability to produce custom colors allows OEMs to color-code different circuit groups for serviceability.
USB cables, HDMI cables, audio cables, charging cables, and fiber-optic patch cords all benefit from a spiral protective outer layer that prevents kinking at connector strain-relief points and provides a premium tactile finish. The small-diameter capability (12–25 mm range) is ideal for this segment, where appearance, flexibility, and durability are purchasing drivers for consumers.
Railway rolling stock and aircraft have stringent requirements for cable protection: flame retardancy, low smoke, halogen-free composition, and extreme temperature tolerance. Spiral hose produced on this line can be formulated to meet these specifications, serving as a protective overwrap for signal, control, and power cables in these safety-critical applications.
Beyond industrial applications, the same spiral hose finds use in pet leashes, toy ropes, sports equipment grips, garden hose protection, and furniture edge trim. The ability to produce in multiple colors and soft-touch formulations opens consumer-product markets that value aesthetics and tactile quality as much as functional performance.
For manufacturers running complementary extrusion businesses — such as PVC WPC foam board extrusion lines or reinforced pipe production lines — adding a spiral hose line diversifies the product portfolio into high-growth cable management markets.
Chenxing Machinery (Zhangjiagang Chenxing Machinery Co., Ltd.) brings decades of plastics extrusion engineering expertise to every line we deliver. Our spiral hose production systems are installed and operating in factories across Asia, the Middle East, Africa, and South America, producing millions of meters of cable protection hose annually.
Engineering-Grade Components: We do not cut corners on critical wear parts. The 38CrMoAlA nitrided screw and barrel, PID temperature controllers, and heavy-gauge structural frames are specified for industrial-duty service life — not for a price point.
Complete System Integration: You receive a pre-commissioned, factory-tested line, not a collection of components to integrate on-site. Our engineers handle mechanical alignment, electrical synchronization, and process parameter optimization during installation and commissioning.
Comprehensive After-Sales Support: From operator training to spare parts supply to remote troubleshooting, we stay with you through the life of the equipment. Our technical team can provide process recipes for new materials, tooling design for custom profiles, and upgrade recommendations as your business grows.
Proven Ecosystem: The spiral hose line fits into a complete plastics processing ecosystem that includes plastic grinding machines, SMF disc grinding pulverizers, ZSQ vibrating screens, and plastic pelletizers. Manufacturers who source multiple machines from Chenxing benefit from unified service, common spare parts, and integrated process support.
The CY designation indicates a lower-speed configuration (typically 10–160 r/min or 10–90 r/min), which is better suited for processing higher-viscosity materials, thicker-walled products, and formulations with fillers that require longer residence time for complete plasticization. The HY designation denotes a higher-speed configuration (16–160 r/min), optimized for high-throughput production of standard-grade PP and PE formulations where maximum output rate is the priority. If you are producing large-diameter, thick-wall hose or running PVC formulations (which are more thermally sensitive), a CY model is recommended. For high-volume PP production of thin-to-medium-wall hose, an HY model will maximize your return on investment. Our application engineers can analyze your specific material and product requirements to recommend the optimal configuration.
Yes, the line supports full-color customization. Color is introduced via masterbatch — pre-dispersed pigment pellets that are metered into the extruder hopper alongside the base polymer. A color change typically involves purging the barrel with a cleaning compound or the next production color until the extrudate runs clean, then starting the new color. For frequent color changes, we recommend maintaining a dedicated screw and barrel set for light colors (white, yellow) and another for dark colors (black, blue) to eliminate cross-contamination risk. The PID temperature controllers, high-speed mixer, and automatic feeding machine all support rapid material transitions.
Standard lead time for a complete six-unit line (extruder, rotary former, haul-off, cooling tank, meter counter, winder) is approximately 45–60 working days from order confirmation, depending on the specific extruder model, optional add-ons, and current production queue. Custom die head profiles or non-standard winding configurations may extend this by 10–15 days. We recommend placing orders with a 90-day buffer before your target production start date to allow for shipping, customs clearance, installation, and commissioning. Rush orders can be accommodated on a case-by-case basis — contact Nicole for current availability.
The line requires: (1) Three-phase electrical power — voltage and frequency per your regional standard (380V/50Hz, 440V/60Hz, etc.), with the total connected load varying by extruder model (refer to the drive power column in the specifications table); (2) Process cooling water — supplied by an industrial chiller for the cooling tank closed loop; (3) Compressed air at 0.6–0.8 MPa for pneumatic actuators and controls; (4) Floor space — approximately 12–18 meters linear length (depending on cooling tank configuration) by 2–3 meters width. Our installation team provides detailed foundation drawings and utility connection specifications well in advance of equipment shipment.
Diameter changeover requires a tooling swap on the rotary forming head — specifically the forming mandrel, sizing rings, and guide rollers. A trained operator can complete a full diameter changeover in approximately 60–90 minutes. For manufacturers running a limited set of diameters (e.g., primarily 25 mm, 50 mm, and 80 mm), we recommend purchasing pre-configured quick-change tooling cassettes for each diameter to reduce changeover time to under 30 minutes. The line does not require mechanical re-alignment between diameter changes because the forming machine and downstream equipment are designed with common centerline heights.
Our after-sales package includes: on-site commissioning by a Chenxing engineer (typically 5–7 working days covering mechanical alignment, electrical check-out, dry-run testing, and production trial with your material); operator training covering machine operation, basic troubleshooting, daily maintenance, and safety protocols; a 12-month warranty on all Chenxing-manufactured components against defects in materials and workmanship; remote technical support via video call, email, and messaging; and a spare parts program with stocked critical wear items (screw, barrel, heaters, thermocouples, seals, belts) available for express shipment. Extended warranty and annual preventive maintenance contracts are available on request.
Yes. The screw and barrel metallurgy (38CrMoAlA) is compatible with flame-retardant additive systems, and the PID temperature controllers provide the precise thermal management required when processing FR compounds — which often have narrower processing windows and higher sensitivity to temperature excursions. Achieving UL94 V-0 or equivalent ratings depends primarily on the compound formulation (base polymer + FR additive package), not on the extrusion equipment. We can recommend qualified compound suppliers and share processing guidelines based on our laboratory trials and customer production experience. For manufacturers already working with a specific FR compound, we can run a trial on our in-house line to validate processability before delivery.
Ready to add spiral cable protection hose to your product portfolio? Our team is prepared to support you from initial consultation through installation and production ramp-up. Here is how the process works:
Step 1 — Define Your Requirements: Tell us your target product range (pipe diameters, materials, colors), desired annual output, available factory utilities, and any special requirements (flame retardancy, UV resistance, custom colors). The more detail you provide, the more precise our quotation will be.
Step 2 — Receive Your Custom Proposal: Based on your specifications, we will recommend the optimal extruder model, downstream configuration, and optional add-ons. You will receive a detailed commercial offer including equipment list, technical specifications, delivery timeline, and pricing within 2–3 working days.
Step 3 — Factory Visit or Virtual Tour: We welcome you to visit our manufacturing facility in Zhangjiagang, China, to see the equipment under assembly, witness a production trial, and meet our engineering team. If travel is not feasible, we offer a comprehensive virtual factory tour with live video walkthrough and real-time Q&A.
Step 4 — Order, Production & Commissioning: Upon order confirmation, we begin manufacturing your line. Throughout the production cycle, we provide progress updates with photos and videos. When the line is ready, our engineer travels to your site for installation, commissioning, and operator training — ensuring you are producing saleable product from day one.
Contact us today to discuss your spiral hose production requirements:
Contact Person: Nicole
Phone / WhatsApp: +86 159 5118 7228
Email: ceo@cxsljx.com
Company: Zhangjiagang Chenxing Machinery Co., Ltd.
Website: www.chenxingmachinery.com
