Being founded in 2004 Polycab Ltd.

is specialized in HFFR, XLPE and PEX for cable and

pipe applications. The founding partner Mehmet Kaya is in cable sector since 1998 when
he first started his career as the purchasing manager of Telerko Cable Co. followed by the
same position in ETA Cable Co. till 2003.
Below you will find an article he shares his experience gained in years about HFFR
extrusion with cable manufacturers.

BASICS OF HFFR EXTRUSION

HFFR (Halogen Free Flame Retardant) materials are actually compounds
mainly

consisting

Hydroxide

(ATH)

retardant

material

of

and

Ethylene

Vinyl

Polyethylene
ATH

is

Acetate

(PE).

replaced

by

In

(EVA),

some

Magnesium

Aluminum

Tri

grades

the

flame

Oxide

but

being

relatively more expensive these compounds are not preferred by cable

manufacturers. Some other abbreviations like LSFOH (Low Smoke Fume Zero
Halogen), LSZH (Low Smoke Zero Halogen) or FRNC (Flame Retardant Non
Corrosive) may also be used instead of HFFR. However such products are
commonly known and named as HFFR in Turkey.
Being in the sector for approximately 18 years we have had the chance
to witness the tremendous increase in the consumption of HFFR compounds
especially in last 5-6 years and we felt ourselves obliged to share our
experience in HFFR extrusion with people who need it regardless they
are our customers or not. A great deal of the information given below
may sound very simple for those who are very familiar with the product
but in this article we determined our target as giving a clear idea

Sahrayicedid Mah. Guzide Sk. Mist Is Merkezi, Kat:6 Daire:12 Kadikoy 34734 Istanbul
Phone : + 90 216 385 2553

Fax : + 90 216 885 0043

www.polycab.com.tr

E-mail : info@polycab.com.tr

about basics of HFFR extrusion to new beginners or relatively less

experienced manufacturers in order to eliminate try & error method when
they first start the process trials with such products . And we believe
that even experts will find one or two interesting tips.
1- Because of ATH content, HFFR compounds are very sensitive against
humidity. The reason being that, the original packages shall be
stocked in a dry/cool place and shall be opened just before use.
2- Thermoplastic

compounds

suspected

to

be

humid

can

be

used

successfully after drying in the oven, in the dryer or in the

de-humidifier at 60-70 C for approximately 4 hours. That long
drying is not recommended for thermoset (x-link, cross-linked)
compounds since such a process will cause the silane ingredient
(the cross-linking agent) to evaporate.
3- Any masterbach with EVA or PE carrier can be used for coloring.
There are two important things you shall pay attention when using
the color masterbatch; first you shall make sure that the color
masterbatch you are using is not wet or humid. Second, you shall
not exceed 1,5% concentration. Over-doze color masterbatch may
harm the flame retardancy properties of the compound.

Therefore

in order to get the demanded color it is recommended to use a

masterbatch

with

higher

pigment

rate

rather

than

using

more

quantity of color masterbatch.

Sahrayicedid Mah. Guzide Sk. Mist Is Merkezi, Kat:6 Daire:12 Kadikoy 34734 Istanbul
Phone : + 90 216 385 2553

Fax : + 90 216 885 0043

www.polycab.com.tr

E-mail : info@polycab.com.tr

4- 170oC is the critical temperature treshold in HFFR extrusion. Over

170oC the flame retardant ATH decomposes and the outcome is water.
Actually this property of ATH is what makes the compound flame
retardant. During a fire the ATH faces high heat so produces
water that either extinguishes the flame or prevents and slows
down the flame propagation. You can easily observe this property
by litting an HFFR insulated cable. The bubbles you will observe
on the surface and in the flame is just water ! If 170oC is
exceeded during the extrusion process then the evaporating water
will penetrate the compound to create bubbles like foaming which
negatively effects the mechanical and fire retardancy properties
of the compound.
5- Bubble

check

can

be

done

by

sheathing/insulation

longitudinally

magnifier

microscope

or

under

or

two

methods:

and

check

check

the

Cut

bubbles
density

the
by

of

a
the

insulation/sheathing material after extrusion. A compound that has

1,50 g/cm3 granule density shall give a value around 1,46-1,48
g/cm3

after

extrusion.

Lower

density

points

out

micro-bubble

formation named foaming.

Sahrayicedid Mah. Guzide Sk. Mist Is Merkezi, Kat:6 Daire:12 Kadikoy 34734 Istanbul
Phone : + 90 216 385 2553

Fax : + 90 216 885 0043

www.polycab.com.tr

E-mail : info@polycab.com.tr

6- There may be various reasons for the temperature to exceed 170oC

6a-

Malfunctioning thermocouples, resistances or fans.

6b-

Using a high compession screw.(Recommended compression rate

1:1.12 - 1:1.20)

6c-

Increasing compression rate because of barriers and/or mixing

& compressing zones on the screw.

6d-

Sharp angle or very narrow passages between the barrel, the

neck and the cross-head of the extruder.

6e-

Using

PVC

type

material-distributor

(commonly

known

as

torpeedo) with very narrow and shallow channels.

6f-

Using mesh.

6g-

Increasing the pressure in the cross-head by using improper

extrusion tooling (tip & die).

6h-

Employing a very big extruder for the extrusion of low crosssection cables.

Sahrayicedid Mah. Guzide Sk. Mist Is Merkezi, Kat:6 Daire:12 Kadikoy 34734 Istanbul
Phone : + 90 216 385 2553

Fax : + 90 216 885 0043

www.polycab.com.tr

E-mail : info@polycab.com.tr

7- The

main

principle

uncontrolled

of

pressure

HFFR

and

heat

extrusion
increase

is
in

never
any

allowing

zone

of

the

extruder and the cross-head. Increasing pressure may act as a

barrier on the screw causing the material re-cycle in the barrel
which will lead uncontrolled increase in the heat due to friction.
8- Non-contact infrared thermometers are useful to cross-check the
heat

by

means

of

measuring

the

temperature

of

the

outflowing

compound.
9- The cooling water shall be heated up to 30-40oC especially in the
winter time. If the hot cable enters very cold water at ambient
temperature

then

HFFR

is

shocked

to

loose

its

mechanical

properties.
10- Low heat profile (Around 150oC at the cross-head) also results in
sudden decrease in mechanical properties, especially in elongation
at break. This practice is named as cold extrusion which also
effects the tear strength (crack resistance) of the sheathing.
11- Wet or humid color masterbatch also causes bubble formation.
12- Remainings of PVC in the barrel or on the screw or using a color
masterbatch with PVC carrier by mistake causes HFFR compound to
decay & get a styropor-styrofoam like structure.

Sahrayicedid Mah. Guzide Sk. Mist Is Merkezi, Kat:6 Daire:12 Kadikoy 34734 Istanbul
Phone : + 90 216 385 2553

Fax : + 90 216 885 0043

www.polycab.com.tr

E-mail : info@polycab.com.tr

13- In cable standards the expected mechanical performance of HFFR

insulation and sheathing compounds are generally given as 9-10 N
tensile strength and 125% elongation at break. Great deal of cable
manufacturers are satisfied when they catch these values and give
up

trying

to

improve

the

mechanical

properties.

It

is

hardly

recommended that cable manufacturers shall continue trials until

they improve the mechanical values of the finished product to the
levels indicated in the technical data sheet (11-12 N tensile
strength & 150-200% elongation at break) of the compound they are
using. If you are habitually satisfied with the values at the
limits then even 10% decrease in these values due to a minor
problem that can be faced anytime during the extrusion process may
result that your cable will be scrap because it will not meet the
standards anymore. But if you catch the values stated in the
technical data sheet then you will have a buffer zone so your
cable will still be usable even in case of 10-15% loss in the
mechanical performance.
14- One

of

the

major

problems

that

cable

manufacturers

face

is

successfully passing the vertical burning test generally known as

ladder test. For success in IEC 332/3 vertical burning test, the
cable construction, extrusion conditions and the appropriateness
of the burning chamber to the standards are as important as the
compound itself. Longitudinal holes in the cable due to bad
construction

(like

undesired

gaps

or

air

pockets

between

insulations or between the outer sheathing and the insulations

caused by not using a proper bedding)

will perform as a chimney

during the test and this will cause the cable start burning from

Sahrayicedid Mah. Guzide Sk. Mist Is Merkezi, Kat:6 Daire:12 Kadikoy 34734 Istanbul
Phone : + 90 216 385 2553

Fax : + 90 216 885 0043

www.polycab.com.tr

E-mail : info@polycab.com.tr

the inner side. Or as mentioned above if the ATH is decomposed due

to

improper

extrusion

conditions,

this

also

leads

decrease in the flame retardancy properties of the cable.

sudden
Under

normal conditions any HFFR compound with 34 or more LOI value

performs well in the ladder test.
15- There is a common belief among cable manufacturers that being
cross-linked thermoset HFFR compounds are to be extruded the
same

way

as

XLPE

(cross-linked

polyethylene),

with

high

compression screw and tooling. In fact this logic is completely

wrong. Thermoset HFFR compounds must be extruded under exactly the
same conditions with thermoplastic ones.

Please do not hesitate to contact us for any further technical

information or about technical difficulties you may be facing with HFFR
compounds. It will be our great pleasure to assist you.

www.polycab.com.tr info@polycab.com.tr

Sahrayicedid Mah. Guzide Sk. Mist Is Merkezi, Kat:6 Daire:12 Kadikoy 34734 Istanbul
Phone : + 90 216 385 2553

Fax : + 90 216 885 0043

www.polycab.com.tr

E-mail : info@polycab.com.tr