As cable manufacturers face increasing demands for higher-performance materials, diverse cable constructions, tighter process tolerances and demanding production conditions, extrusion technology is evolving to deliver greater process stability, flexibility and precision. During an exclusive interview with Wire & Cable India, Dr. Mikko Lahti, R&D Director, Maillefer, shares insights into how advanced automation, data acquisition, intelligent control systems, digital process monitoring and data-driven optimisation are providing measurable benefits to manufacturers. He stresses output stability as one of the most important contributors to overall production economics. Looking ahead, he highlights process modelling, digital factory simulation, real-time quality monitoring and integrated data management as key capabilities shaping the future of extrusion systems.
Wire and Cable India: Which developments are placing the greatest demands on modern extrusion systems, and why?
Mikko Lahti: Today’s extrusion systems must cope with an unprecedented range of cable constructions, materials and application requirements. Growth in automotive electrification, renewable energy, HVDC transmission, data communication and fire-safe building cables is driving demand for higher-performance materials and tighter process tolerances. At the same time, manufacturers are expected to deliver higher output rates while reducing material consumption and energy use.
These trends place increasing demands on extrusion stability, melt quality, dimensional accuracy and process repeatability. Modern extrusion lines must be flexible enough to process a broad spectrum of materials, from XLPE and HFFR compounds to advanced thermoplastics, while maintaining consistent product quality at high production speeds.
Watch: Top Cable Companies in India
WCI: Compared with five years ago, which aspects of the extrusion process have become technically more difficult to control consistently?
ML: The biggest challenge is maintaining stable output and consistent melt quality across increasingly diverse materials and production conditions. As cable designs become more material-efficient, acceptable process variation decreases, placing greater emphasis on output linearity, temperature control and dimensional consistency.
To address these demands, extrusion technology has evolved toward advanced automation, data acquisition, digital process monitoring and intelligent control systems. Process modelling, neural-network-based optimisation and factory-level performance analysis are increasingly used to determine optimal operating conditions and maintain productivity while keeping melt temperatures within safe processing limits.
WCI: Which material-related challenges are driving the most significant innovations in extrusion equipment today?
ML: Material diversity is a major driver of innovation. Cable manufacturers increasingly process XLPE, HFFR, LSZH compounds, thermoplastic elastomers and other specialized materials, each requiring specific screw designs, processing conditions and tooling solutions.
From an equipment perspective, the challenge is to ensure stable processing windows and excellent melt homogeneity across multiple material families. This is why modern extrusion systems increasingly feature application-specific screw designs, optimized feeding technologies and advanced process simulations that help define ideal temperature profiles and operating conditions.
A key bottleneck in HVDC cable manufacturing is line speed-the rate at which HVDC cables are produced. Conventional manufacturing processes, while reliable, may lack the throughput required to meet accelerating demand. Enhancing line speed without compromising cable quality is essential to support the rapid deployment of HVDC infrastructure aligned with global energy transition goals.
WCI: Where do machinery builders encounter the greatest trade-offs between productivity, process stability and product quality?
ML: The most common trade-off arises when manufacturers seek higher line speeds without compromising dimensional accuracy, concentricity or insulation quality. Increasing output alone does not necessarily improve productivity if process stability deteriorates or scrap levels increase.
Maillefer emphasizes that output stability is one of the most important contributors to overall production economics. Stable extrusion across the entire operating range allows manufacturers to achieve higher productivity with lower scrap rates, fewer operator interventions, and better Overall Equipment Effectiveness (OEE). Advanced extrusion concepts and optimized curing technologies are therefore designed to increase capacity while simultaneously improving cable quality.
WCI: Which developments are delivering the greatest measurable operational benefits today, and where does a gap still exist between expectations and implementation?
ML: Automation, process monitoring and data-driven optimization currently provide some of the most measurable benefits. These technologies improve consistency, reduce scrap, support minimum tolerance production and allow operators to better understand process performance. Advanced data acquisition and production analysis tools make it possible to identify inefficiencies and optimize both energy and material consumption.
A gap still exists in the industry’s ability to fully utilize the large amount of production data available. While digitalization, AI and Industry 4.0 technologies offer significant potential, achieving practical value depends on combining technology with process know-how and a deep understanding of extrusion behavior.
Process modeling, digital factory simulation, real-time quality monitoring and integrated data management will play a central role. Future extrusion systems will combine high productivity with optimized energy consumption, reduced material usage and greater production flexibility, enabling cable manufacturers to respond rapidly to changing market requirements while maintaining exceptional product quality.
WCI: Which factors now have the greatest influence on the investment value of an extrusion line?
ML: Investment decisions increasingly focus on total value generation rather than machine output alone. Key factors include material savings, reduction of scrap, output stability, energy efficiency, operational flexibility and long-term productivity.
Manufacturers also seek equipment that can respond to changing market demand by processing different cable types and materials efficiently. Flexible production concepts that allow the same line to support multiple applications improve investment security and long-term competitiveness.
WCI: How are renewable energy, EV, automotive, railway, data communication and specialty cable applications influencing machine design?
ML: These sectors are pushing manufacturers toward increasingly specialized cable designs and higher quality requirements. Automotive applications require thin-wall insulation and efficient material usage. Renewable energy and power transmission applications demand advanced insulation technologies and highly reliable production processes. Data communication cables require extremely consistent dimensions and process precision.
As a result, machine designs are becoming more application-oriented, incorporating specialized crossheads, optimized extruders, advanced measurement technologies and process-specific production concepts that improve both quality and efficiency.
WCI: What misconceptions about extrusion often lead to avoidable quality issues, inefficiencies or higher production costs?
ML: One common misconception is that maximum output automatically delivers maximum profitability. In practice, unstable production, excessive material usage and scrap generation can easily outweigh the benefits of higher nominal throughput.
Another misconception is underestimating the importance of process stability and extrusion know-how. High-performing plants consistently focus on maintaining stable operating conditions, optimizing temperature profiles, controlling material use and continuously analyzing production performance. They treat extrusion as a complete process rather than simply a machine operation.
Also Read: Wire & Cable India Emagazine Sep-Oct Issue 2026
WCI: Which engineering capabilities will define the next generation of extrusion machinery?
ML: The next generation of extrusion systems will be characterized by intelligent process control, advanced automation, AI-assisted quality management and increasingly sophisticated data analytics. Manufacturers will expect machines not only to produce cables efficiently but also to provide actionable insights that continuously improve performance.
Process modeling, digital factory simulation, real-time quality monitoring and integrated data management will play a central role. Future extrusion systems will combine high productivity with optimized energy consumption, reduced material usage and greater production flexibility, enabling cable manufacturers to respond rapidly to changing market requirements while maintaining exceptional product quality.
While digitalization, AI and Industry 4.0 technologies offer significant potential, achieving practical value depends on combining technology with process know-how and a deep understanding of extrusion behavior.
