Revolutionizing Production at Camuna Cavi: A New Era for Special Cables
Camuna Cavi has taken a significant step forward in innovation and efficiency with the installation of a brand-new insulation line.
This investment is a key milestone in the company’s commitment to Strategy of the Group, reinforcing its leadership in the Special Cables industry.
The decision to replace two aging insulation lines with a state-of-the-art system was driven by the need for greater flexibility, energy efficiency, and enhanced production capabilities.
"The old lines had been in operation for over 30 years and were reaching their limits in terms of capacity and maintenance costs”, explains Luigi Sterli, Innovation & Technology Manager at Camuna Cavi.
“With the new insulation line, we’ve achieved a production speed three to five times higher, improved quality control, and reduced energy consumption. These enhancements are crucial for maintaining our competitiveness in the Special Cables sector.”
The new insulation line incorporates cutting-edge technology, including a 45 mm diameter primary extruder and a 35 mm diameter co-extruder, utilizing helical technology in the feeding zone of the cylinder to optimize output while minimizing energy consumption and space requirements. It is designed to accommodate a variety of production needs, from small batches with a dedicated single pay-off to large-scale production with dual flyer pay-off and an automatic take-up system.
“Our goal was not only to improve efficiency but also to ensure superior product quality”, adds Sterli.
“The system is equipped with advanced quality control mechanisms, such as a high-resolution camera for marking verification and sensors for diameter and eccentricity measurement. This allows us to maintain precise insulation thickness and reduce material waste.”
Measurable Benefits and Future Outlook
Beyond increased productivity, the new line has unlocked significant economic and operational advantages:
More than doubled production output in kilometers with the same workforce.
30% reduction in energy consumption (kWh/km).
Government incentives up to 45 % under Italy’s Industry 5.0 program.
100 m² of freed-up space due to the removal of outdated machinery.
- Less waste through optimized material use and advanced production techniques.
Looking ahead, the company expects to further enhance its competitiveness and improve delivery times for Special Cables, particularly for sections ranging from 0.25 mm² to 4 mm², where previous production faced challenges.
“This investment is a game-changer for us,” says Giovanni Pelà, Managing Director Camuna Cavi.
“We have successfully implemented a cutting-edge solution in record time - just seven months from approval to full operation. This is a reflection of our team’s dedication and our commitment to staying ahead in the Special Cables industry.”
