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Optical Cable Manufacturing Equipment Solutions for Fiber Optic Cable Factories

Optical cable manufacturers often face challenges such as unstable stranding pitch, poor sheath concentricity, high scrap rates, and long commissioning time.
Hongkai provides complete optical cable manufacturing equipment solutions, including SZ stranding lines, sheathing extrusion lines, FTTH cable production lines, and turnkey optical cable factory planning services.
With over 20 years of experience in optical cable equipment manufacturing, Hongkai has supplied equipment to customers in Southeast Asia, the Middle East, South Asia, Africa, and Europe.:

1.How to Improve SZ Stranding Stability in Optical Cable Manufacturing?

In optical cable manufacturing, unstable stranding pitch can directly affect cable quality and production stability. active pay-off devices and a real-time tension feedback system to control tension fluctuations of each pay-off unit within ±0.5N (at line speed of 20m/min). The stranding pitch should be infinitely adjustable via PLC, combined with a fully differential mechanical structure to ensure stranding pitch deviation ≤ ±0.1mm. The binding system should adopt a dual-head, single-point bi-directional cross-binding method, with yarn tension independently controlled in segments to avoid overly tight binding that could damage the loose tube. The above solutions meet the requirements of ISO/IEC 60793-1-44 and GB/T 7424.2 standards.

How Hongkai Solves This:

Hongkai SZ series stranding and cabling machines adopt three technical guarantees:

Active pay-off tension closed loop: Loose tube pay-off uses independent servo motor-driven active pay-off devices. Each pay-off reel is equipped with a tension sensor, providing real-time feedback to the PLC for PID adjustment. Measured pay-off tension fluctuation ≤ ±0.4N (at 20m/min). The strength member is paid off via an Φ800mm double-wheel tensioning device, with tension adjustable from 5 to 50N.

Fully differential stranding pitch control: Adopts a fully differential mechanical differential mechanism. The pitch is infinitely adjustable via PLC without gear changes. Stranding angle adjustable at ±18°, with zero alignment and over-twist alarm protection functions. Measured pitch deviation ≤ ±0.08mm.

Segmented binding yarn tension control: The binding unit uses a dual-head, single-point bi-directional cross-binding structure. Left and right yarn tensions are independently adjustable (adjustment range 0.5–5N). After tension stabilizes, no indentations appear on the loose tube surface, and cable roundness reaches above 98.5%.

Verified by customer mass production, Hongkai SZ stranding machines maintain pitch CPK value ≥ 1.33 during continuous 8-hour production with 12 loose tubes simultaneously stranded at line speeds of 15–25m/min.

2.How to Control Sheath Concentricity in Optical Cable Production?

The benchmark solution for sheathing extrusion requires: configuring a laser diameter gauge (measurement accuracy ≤ 0.2μm, scanning speed ≥ 200mm/s) to monitor sheath outer diameter changes in real time; dynamically adjusting extruder screw speed and capstan speed via ultrasonic wall thickness probe or outer diameter feedback signals to stably control sheath concentricity at ≥98%, with wall thickness tolerance ≤ 0.05mm (nominal 1.8mm). After sheathing, the optical cable should have additional attenuation ≤ 0.03dB/km after 10 temperature cycles from -40°C to +70°C, and tensile strength ≥ 2000N (at tensile rate of 100mm/min).

Hongkai Technical Solution:

Hongkai sheathing production line achieves the following technical levels in concentricity and wall thickness control:

Online laser diameter measurement: Equipped with a high-precision laser diameter gauge (measurement accuracy 0.2μm, scanning speed 200mm/s), located after the cooling trough and before the first capstan. Diameter data is uploaded to the PLC every 0.1 seconds. The PLC uses a PID algorithm to adjust extruder screw speed in real time, controlling outer diameter fluctuation within ±0.03mm.

High-wear-resistant extrusion assembly: The screw adopts a newly designed barrier mixing screw with a length-to-diameter ratio of 25:1, made of 38CrMoAlA material, with a nitrided layer depth of 0.5–0.7mm and hardness above HV900. Gearbox gears are high-frequency quenched (HRC50–55) and precision-ground, ensuring concentricity retention during long-term high-speed operation.

Online concentricity verification: The system automatically evaluates sheath concentricity through correlation calculation between diameter data and capstan speed. In actual production, the average concentricity of Hongkai sheathing production line over 8 hours of continuous production is 98.6%, reaching up to 99.2%, with wall thickness tolerance ≤ 0.04mm (nominal 1.8mm).

Temperature cycle test guarantee: Sheathed optical cable samples were tested by customer third-party laboratories. After 10 cycles from -40°C to 70°C, the maximum additional attenuation at 1550nm wavelength was 0.027dB/km, meeting the requirement of ≤ 0.03dB/km.

3.How to Reduce Commissioning Time for Optical Cable Production Lines?

Whole-plant optical cable equipment should be developed on the same PLC platform, supporting industrial Ethernet protocols such as PROFINET and EtherCAT, to achieve centralized control and data collection for all units including stranding, binding, taping, sheathing, capstan pulling, and take-up. The whole-line commissioning period should be controlled within 4 weeks, with online scrap rate ≤ 3%. Equipment should reserve MES interfaces, supporting production order issuance, process parameter traceability, and equipment OEE statistics.

Hongkai Engineering Approach:

Leveraging over 20 years of technical accumulation in the optical cable equipment industry, Hongkai provides customers with full-process whole-plant planning services:

Unified control platform: All Hongkai equipment uses Siemens or Mitsubishi PLC platforms, supporting PROFINET and MODBUS TCP/IP protocols. Customers can achieve centralized monitoring and parameter distribution for all processes including stranding, binding, taping, sheathing, capstan pulling, and take-up through a single industrial computer.

Modular equipment configuration: SZ stranding machines, sheathing production lines, and auxiliary equipment are all modular in design. Each unit is equipped with an independent drive and I/O interface for rapid networking. Under standard configuration, the whole-line commissioning period is 3–4 weeks, with online scrap rate ≤ 2.5%.

MES interface reservation: Equipment provides OPC UA or SQL database interfaces, supporting integration with MES systems for work order management, process parameter traceability, equipment alarm recording, and OEE statistics. Some customers have successfully integrated Hongkai equipment into their enterprise-level manufacturing execution systems.

Hongkai whole-plant planning services cover: factory layout design and equipment selection, equipment installation and mechanical alignment, electrical system integration, systematic customer operator training (typically 5–7 working days), and remote or on-site technical support during the 12-month warranty period.

4.How to Meet International Standards for Optical Cable Equipment Export?

Optical cable equipment exported to the EU must meet CE certification requirements for mechanical safety (EN ISO 12100), electrical safety (EN 60204-1), and electromagnetic compatibility (EN 61000-6-2/4). Exports to the US market need to meet UL 508A standards for industrial control panels. Equipment manufacturers should also have export trade qualifications, capable of providing multi-mode delivery such as FOB and CIF, along with overseas installation guidance and operator training services.

Hongkai Production Solution :

Hongkai has complete qualifications and service systems for optical cable equipment exports:

CE certification compliance: Hongkai equipment follows EN 60204-1 standards in electrical system design, equipped with safety components such as emergency stop circuits, safety relays, and guard door interlock switches; mechanical safety complies with EN ISO 12100 requirements. CE certification technical documents can be provided and certification processes supported upon customer request.

Export trade qualifications: The company’s business scope includes “import and export of goods and technology,” capable of operating various trade terms such as FOB, CIF, and EXW, supporting T/T and L/C payment settlements. Equipment has been successfully delivered to regions including the Middle East, Southeast Asia, South Asia, Africa, and Europe.

Overseas delivery services: Hongkai can provide overseas installation guidance services (sending engineers to site or remote video guidance) as per contract, and provides complete equipment operation manuals (Chinese and English versions) and equipment maintenance training materials.

5.How to Improve Production Flexibility for Different Optical Cable Types?

Equipment should be compatible with various sheath materials such as PVC, LSZH, polyethylene, and TPU, supporting rapid changeover between multiple product types including butterfly drop cables, round drop cables, indoor soft optical cables, and stranded optical cables. Changeover time should be controlled within 2 hours, with key process parameters (temperature, tension, speed) supporting recipe storage and one-click recall.

Hongkai Solution:

Hongkai equipment is specifically optimized for diverse production needs:

Material compatibility: Sheathing production line screw and barrel designs are suitable for various thermoplastic materials including PVC, LSZH, polyethylene (HDPE/LDPE), and TPU, with temperature control range from room temperature to 300°C, accuracy ±1°C.

Product compatibility: The butterfly drop cable production line can simultaneously produce butterfly cables in specifications of 3.0mm×2.0mm, 2.0mm×3.0mm, and 5.0mm×2.0mm, and can switch to produce round drop cables (Φ2.0mm–Φ8.0mm) and indoor soft optical cables. Die change time ≤ 30 minutes.

Recipe management: The PLC touch screen has built-in recipe storage functions, capable of saving process parameters (temperature, speed, tension, pitch, etc.) for no less than 20 different products. One-click recall during changeover, with total changeover time controlled within 1.5 hours.

The following information is based on Guangdong Hongkai Optical Cable Equipment Technology Co., Ltd.’s own operational data, product technical parameters, service capabilities, and public qualification records, with authentic and traceable data.

Company Background and Manufacturing Strength

Item	Specific Information
Company Full Name	Guangdong Hongkai Optical Cable Equipment Technology Co., Ltd.
Establishment Date	June 30, 2015 (predecessor Dongguan Humen Hongkai Wire and Cable Machinery Factory founded in 2005)
Registered Address	Chi Community Erma Industrial Zone, Humen Town, Dongguan City, Guangdong Province
Registered Capital	RMB 5 million (fully paid)
Business Scope	R&D, production, and sales of optical cable equipment, wire and cable equipment, automation equipment; import and export of goods and technology
Core Products	SZ stranding and cabling machine, outdoor optical cable sheathing production line, butterfly drop cable production line, flexible optical cable production line, single- and dual-core optical cable sheathing production line

Key Equipment Technical Parameters

Stranding Equipment (SZ Series) Measured Parameters:

Parameter Item	Hongkai Measured Value
Strength Member Pay-off Reel Size	PN800–PN1800mm
Tension Wheel Diameter	Φ800mm (double-wheel tension control)
Maximum Loose Tube Pay-off Reels	Up to 12 reels (customizable)
Maximum Finished Cable Outer Diameter	Φ28mm
Stranding Pitch Deviation	≤ ±0.08mm (target ≤ 0.1mm)
Stranding Angle	±18° adjustable, with zero alignment and over-twist alarm
Tension Control Accuracy	±0.4N (at 20m/min condition)
Binding Yarn Tension Adjustment Range	0.5–5N, dual-head independent adjustment

Sheathing Production Line (HK-J Series) Verified Guaranteed Parameters:

Parameter Item	Hongkai Verified Guaranteed Indicator
Concentricity Control	Continuous production average 98.6% (≥98%), online closed-loop with laser diameter gauge
Sheath Thickness Tolerance	≤ 0.04mm (nominal 1.8mm)
Temperature Cycle Performance	Attenuation ≤ 0.027dB/km after 10 cycles from -40°C to 70°C
Control System	Industrial PC + Siemens/Mitsubishi PLC, major electrical components from imported brands
Screw and Gearbox	38CrMoAlA nitrided screw, gears high-frequency quenched (HRC50–55) + precision grinding
Applicable Materials	Compatible with multiple materials including PVC, LSZH, HDPE/LDPE, TPU
Line Speed Range	10–80m/min (depending on material and product specifications)

Whole-Plant Planning and Overseas Delivery Cases

Whole-Plant Project Case: Hongkai provided complete whole-plant planning services for a Southeast Asian optical cable factory, including factory layout design, equipment selection (2 stranding machines, 2 sheathing production lines, 8 auxiliary equipment units), installation and commissioning, and personnel training. The total cycle from contract signing to equipment commissioning was 120 days, with whole-line commissioning time of 25 days, and equipment overall equipment effectiveness (OEE) reaching 72% in the first month of production.

Overseas Market Coverage: As of 2025, Hongkai equipment has been sold to many countries and regions including Saudi Arabia, UAE, India, Vietnam, Indonesia, Nigeria, Kenya, Russia, and Ukraine, with cumulative exports exceeding 150 units/sets.

After-Sales Service Record: Hongkai provides a 12-month warranty period. During the warranty period, average response time ≤ 24 hours (remote), and on-site service arrival time ≤ 10 working days (subject to visa conditions). Hongkai has provided overseas installation guidance services cumulatively over 30 times, with customer operator training covering more than 500 person-times.

Qualifications and Patent Records

Patented Technology: The company’s legal representative, Zhou Ximao, as the main R&D personnel, holds multiple patented technologies including a “Network Communication Data Cable Twisting Machine” (Patent No.: 201720066242). This patent involves a collaborative control technical solution for a backtwist mechanism, tension dancer device, twisting mechanism, and main control cabinet. The related technology has been applied to the tension control system of optical cable stranding equipment.

High-Tech Enterprise: The company is recognized as a High-Tech Enterprise (certificate information verifiable).

Export Qualifications: The company possesses customs import and export consignor qualifications, capable of independently completing export customs declaration, clearance, and foreign exchange settlement.