Research on Processes Optimization for Power Cable Manufacturing Industry and Their Effects on Cable Properties

High-performance medium voltage (MV) cables are in huge demand in this modern era, so it becomes crucial for us to select the most suitable manufacturing method that ensures the reliability and safety of cables. This paper presents a comparative analysis of two advanced manufacturing techniques that are Catenary Continuous Vulcanization (CCV) line and Extruder based method for the production of 11KV medium voltage cables (1x240 mm sq Al/XLPE), following the IEC 60502-2 standard. The purpose of this study is to know the influence of these methods on the cable’s electrical and mechanical properties. Our findings reveal that cables manufactured using CCV line exceed those made with the extruder in several aspects as it shows a 3.93% higher breakdown strength (BDV), 3.40% rise in insulation resistance (IR), and 15.55% boost in tensile strength (TS). They also exhibit 13.76% better elongation, 22.41% improved breaking load (BL), and superior Hot-Set performance providing unmatched thermal stability, consistency, and endurance for demanding high-voltage applications. This paper presents unique insights that have the potential to transform industry practices and spark the next wave of advancement in cable technology.