11/04/2024 – Cable manufacturing

Challenge accepted

Rosendahl Nextrom challenges conventional cable and wire production methods with their latest advancements in manufacturing technology. At the upcoming “wire” trade show, they will showcase a strong portfolio of new and improved solutions for the market.


Nextrom’s induction furnace for optical fiber preforms. © Rosendahl Nextrom


Hairpin extrusion with a newly developed flat crosshead. © Rosendahl Nextrom

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Balancing quality, productivity, and sustainability is an ongoing challenge for cable and wire producers. As a technology leader, Rosendahl Nextrom consistently questions conventional manufacturing methods, and explores possibilities for improvement. Sometimes, a small enhancement to a machine can have a significant impact. At times, it's necessary to rethink the manufacturing process of a product from the ground up.

At “wire 2024”, Rosendahl Nextrom will proudly present their latest advances in manufacturing technology.

Hairpin extrusion: a future-proof solution for e-mobility
Rosendahl has recently introduced the world’s first turnkey extrusion line for hairpin insulation. It makes a safe and reliable power supply at 800V or higher possible. With this solution, the much slower and less efficient enameling process faces strong competition. The exceptionally robust insulation with high-performance plastic will contribute to reduced charging times and increased ranges by minimizing energy losses in electric board systems. This will surely boost the attractiveness of e-mobility.

Increasing production capacity in datacom and telecom
The demand for high-speed data infrastructures continues, as does Rosendahl Nextrom’s R+D work in this area. The company has recently installed the world's most sophisticated laboratory lines for LAN cables and loose tubes at their in-house technology center. Both lines are optimized for high-speed production and equipped with many standout features for scrap reduction, quality control, and automation – an impressive mix of R+D work and engineering excellence to be multiplied in factories worldwide.

Nextrom is revolutionising preform manufacturing with a combination of “Vapor Axial Deposition” and “Outside Vapor Deposition” technologies tailored for producing large-sized preforms with the lowest operational expenses. Furthermore, the telecom fiber drawing process has been optimized to reach impressive speeds of up to 3,500m/min.

The latest achievements in fiber optical cable manufacturing include a high-speed fiber launching system, a high-speed rewinding line and a proof testing and fiber coloring line with automated reel changes. With these new solutions, emphasis was placed on reducing operating time and scrap while increasing productivity, quality, and safety for operators.

Accelerating energy transition
To facilitate and support the industry's shift towards a more sustainable power supply, Rosendahl Nextrom offers a comprehensive set of solutions. Their sustainable concept for forming, welding, and jacketing flexible materials and product sizes on a single production line is well-suited for connecting wind farms, photovoltaic farms, and offshore projects to the power grid.

In the medium-voltage segment, the use of recyclable polypropylene-based compounds eliminates the need for energy-intensive cross-linking. This new manufacturing concept creates a compact and sustainable alternative to conventional XLPE solutions without compromising on electrical properties.

Innovating smart and responsibly
Along with high performance comes high responsibility. A major focus of Rosendahl Nextrom’s efforts is the thoughtful use of materials, waste reduction, minimizing wear, and enhancing energy efficiency.

Their powerful line control offers a wide variety of possibilities to continuously improve production in all those areas. ESG-compliant measurement of CO2 and energy consumption has been added to Rosendahl Nextrom’s smart portfolio, ready to support the green transition in the industry. Another user-friendly yet powerful solution has been designed to simplify the complex task of maintenance management. Customers who integrate it into their workflow can expect increased equipment reliability, reduced downtime, and improved operational efficiency.

In the field of telecom fiber drawing, Nextrom is leading the way towards more sustainable production: A Helium Recovery System recovers up to 90% of the used helium, effectively reducing dependence on this limited resource. The return on investment for this system can be achieved within a year, considering the current prices and availability constraints of helium. Addition, the Nextrom Induction Furnace drastically cuts down on energy consumption.

Offering lifetime support
Rosendahl Nextrom is a strategic partner for producers of cable and wire worldwide. Customers can expect first-class support for the entire lifetime of their machines. To further improve ongoing collaboration, the company has launched a digital customer portal, and improved their warehouse infrastructure. Attractive new service packages and fast, uncomplicated support worldwide round off the selection.

Visit Rosendahl Nextrom’s experts. Explore innovative extrusion technology and sustainable manufacturing solutions with interactive exhibits and experience a touch of magic.

wire 2024, hall 9 booth A 60

Rosendahl Nextrom GmbH
Schachen 57, 8212 Pischelsdorf, Austria
Contact person is Bianca Kranz
Tel.: +43 3113 5100-253