At ABIS International, we do more than design factory layouts; we engineer high-performance manufacturing environments tailored for the modern cable industry.

Our team conducted a full-cycle analysis of the cable production process to design a linear plant layout that enables continuous, interruption-free operations.

The result: smarter movement, reduced waste, and faster throughput.

• Direct material paths from intake to output
• Minimised handling time and transitions
• Elimination of production bottlenecks
• Shortened production cycle

Where Function Meets Form. To ensure maximum safety, flow, and space utilisation, the facility was divided into clearly defined operational zones:

• Cable Manufacturing Process Areas
• Raw Material & Compound Storage
• Quality Control Labs & Final Testing
• Packaging & Finished Goods Shipping
• Maintenance & Utilities Access

We collaborated closely with MEP and facility engineering teams to embed essential utility systems into the layout itself, including:

• Compressed air networks
• Chilled water & process cooling systems
• Power distribution systems
• HVAC, exhaust, and ventilation
• Fire safety & protection System

These systems were designed for optimal performance, easy access, and zero disruption to manufacturing activities.

Built with long-term success in mind, the facility features modular expansion zones that support:

• Seamless addition of new production lines
• Easy integration of future automation systems
• Scalable storage, logistics, and packaging capacity

This forward-thinking approach ensures that the plant grows without disrupting existing operations.

We engineer facilities that support not just machines—but the people who run them. Every element of the layout prioritises operator safety, comfort, and efficiency:

• Clear, compliant footpaths and emergency egress routes
• Smart staff flow separation from material movement
• Ergonomically placed workstations for operator safety
• Intuitive navigation and visibility across zones

At ABIS International, we specialise in the custom design and engineering of Catenary Continuous Vulcanisation (CCV) lines for the cable manufacturing industry.

Our solutions are tailored for high-performance cable production lines, meeting the rigorous demands of today’s medium voltage (MV) and extra-high voltage (EHV) cable systems.

We go beyond standard layouts. Each CCV system we engineer is custom-built for your facility and production goals:

• Optimised Production Layouts – Engineered for smooth material flow and space efficiency
• Advanced Automation Integration – Real-time monitoring and process control for cable extrusion systems
• Flexible Configurations – Compatible with XLPE, rubber, and other cable insulation materials
• Modular Design – Scalable for future upgrades or increased cable production capacity

• Tailored CCV Layouts – Built to match your cable manufacturing equipment and specifications
• Efficient Process Design – Reduce handling time and setup through intelligent engineering
• Scalability – Easily expand production for evolving power cable manufacturing needs
• Safety & Compliance – Meets global standards for HV and EHV cable production
• Complete Project Support – From layout concept to on-site commissioning

Our custom CCV systems are ideal for a range of cable manufacturing applications, including:

• Medium Voltage Cable Production (6kV–35kV)
• High Voltage (HV) and Extra-High Voltage (EHV) Cable Manufacturing
• Utility, Wind Energy, and Industrial Cable Systems
• Renewable Power Cable Infrastructure

Clients using ABIS-engineered CCV lines for cable production benefit from:

• Higher output per shift
• Reduced cable defect rates
• Faster changeovers in cable extrusion lines
• Consistent cable quality meeting IEC/IEEE standards

Whether you are upgrading an existing plant or developing a new cable manufacturing facility, our engineering team is ready to design a scalable, efficient CCV layout that accelerates your production.

• Enhancing throughput without expanding footprint
• Adding automation and control systems to legacy equipment
• Phased implementation to maintain production during upgrades

Our Utilities Engineering Design Service covers every critical infrastructure system that powers your plant, including:

• Compressed Air Systems
• Chilled and Cooling Water Networks
• Steam and Condensate Systems
• Electrical and Power Distribution
• Vacuum, Process Water & Hydraulic Systems
• Fire safety & protection System

At ABIS International, we specialise in the design of Utilities Engineering Networks for factories, from cable manufacturing plants to a wide range of industrial facilities.

Our approach ensures efficient, reliable, and safe distribution of essential services like compressed air, chilled water, steam, and electrical power.

ABIS specialises in designing and implementing corrosion-resistant compressed air networks for factories that utilise pneumatic systems.

Additionally, ABIS will create and install a ventilation system for compressors, complete with air dryers.

This system includes moisture and impurity filtering and purification units for compressed air, ensuring the pneumatic network is protected from damage and malfunction.

ABIS engineers are prepared to conduct comprehensive studies, design, and implement chilled water system networks for factories and other establishments that require cold water.

This includes the development of heat exchanger networks designed to cool products or the surrounding environment.

ABIS offers a comprehensive study, design, implementation, and commissioning of industrial boiler distribution networks that supply factories and industrial establishments with the necessary hot water and steam.

At ABIS, we are dedicated to conducting comprehensive studies, designing, and implementing overhead cable trays and low-voltage networks for factories.

We carefully consider the detailed calculations of the cables used and the electrical loads of the machines and facilities.

Ensuring Precision in Cable Extrusion

Air vacuum systems are essential in cable extrusion lines to maintain uniform insulation thickness and eliminate air bubbles during sheath application.

Applications include:

• Providing stable negative pressure for extruder crossheads.
• Ensuring smooth insulation and sheathing of cables.
• Reducing defects caused by trapped air or voids.
• Enhancing overall cable quality and longevity.

Cooling & Temperature Control for Reliable Production

Process water is one of the most vital utilities in a cable factory, primarily used in cooling troughs and water baths during cable extrusion.

Applications include:

• Cooling of extruded cables to ensure proper solidification.
• Closed-loop water circulation systems for energy and cost efficiency.
• Water treatment and filtration for consistent cooling performance.
• Temperature regulation to maintain dimensional accuracy and product quality.

Powering Heavy-Duty Cable Manufacturing Equipment

Hydraulic systems are the backbone of many mechanical operations within a cable factory. They provide the force needed for:

• Stranding and armoring machines.
• Cable coiling, cutting, and handling equipment.
• Presses, pullers, and other heavy-duty machinery.

Benefits of hydraulic systems in cable factories:

• High reliability under continuous operation.
• Smooth, controlled power for precision processes.
• Reduced mechanical wear and extended equipment lifespan.

Cable factories face unique fire risks due to the presence of flammable materials such as PVC, polyethene, insulation compounds, lubricants, and packaging.

High heat from extrusion machines, electrical faults, and dust accumulation can rapidly escalate into dangerous fires if not managed effectively.

A well-designed combination of air vacuum, process water, and hydraulic systems ensures:

• Improved production efficiency.
• Enhanced product consistency and quality.
• Energy savings through optimised system design.
• Reduced operational costs and downtime.
• Compliance with industry safety and environmental standards.

We specialize in the design, installation, and maintenance of utility systems tailored to cable manufacturing operations.

Our solutions are engineered for efficiency, reliability, and scalability, helping you achieve world-class production standards.