Sports, Fitness, and Safety Rope Extrusion Line

Sports, Fitness, and Safety Rope Extrusion Line

A sports, fitness, and safety protection rope extrusion production line is a specialized automated industrial equipment used for producing high-performance fiber ropes. These ropes have extremely high requirements for strength, wear resistance, weather resistance, and safety. The production line manufactures rope products that meet specific applications by processing polymer materials (such as nylon, polyester, polypropylene, etc.) through melting, extrusion, stretching, and winding processes.
Its core process is "extrusion-stretching-setting." By precisely controlling temperature, tension, and speed, the polymer molecular chains become highly oriented and crystalline, thereby endowing the rope with extremely high breaking strength and low elongation.

Main Components

A complete rope extrusion production line typically consists of the following core systems, which work together to achieve continuous automated production from plastic pellets to finished rope.
Pay-off System
Function: Used to place and feed the rope core (if required). Many high-performance ropes, such as climbing ropes and safety ropes, use a "sheath-core structure," where the interior consists of load-bearing core yarns and the exterior is a wear-resistant sheath.
Composition: Pay-off stand, tension controller. Ensures the core yarn maintains constant and appropriate tension when entering the extruder head.
Extrusion System
Function: This is the "heart" of the production line, responsible for melting and plasticizing solid plastic pellets and continuously extruding them through a die to coat the core yarn, forming the rope preform.
Composition:
Hopper: Used for storing and conveying raw material pellets.
Extruder: Contains a heated barrel and a screw. The rotating screw shears, conveys, and melts the material, while the heated barrel provides heat to turn the material into a homogeneous melt.
Die Head and Die: Key components. The melt is given its specific shape here and precisely coats the moving core yarn.
Cooling and Setting System
Function: Rapidly cools and solidifies the high-temperature molten rope preform exiting the die orifice, setting it into its final geometric shape.
Composition: Cooling water tank or cooling water ring. Uses circulating cooling water for rapid temperature reduction.
Stretching and Heat Treatment System (Drawing and Setting)
Function: This is the key stage determining the mechanical properties of the rope.
Stretching: Applies high tension to the cooled rope through multiple sets of traction rollers with progressively increasing speeds, stretching the molecular chains, orienting them, and promoting crystallization. This significantly increases strength and reduces elongation.
Heat Treatment (Heat Setting): Applies gentle heat to the rope under tension to relieve internal stresses, stabilize the rope's dimensions and performance, and prevent excessive shrinkage or deformation during future use.
Composition: Multiple sets of traction rollers, hot air oven, or hot water tank.
Take-up System
Function: Winds the final formed rope onto a spool or reel in a neat manner with constant tension, facilitating packaging, transportation, and use.
Composition: Take-up machine, tension control system, and traverser.
Electrical and Control System
Function: The brain of the production line. Uses a PLC (Programmable Logic Controller) and a touchscreen HMI (Human-Machine Interface) to centrally control key parameters of the entire production process, such as temperature, speeds in various sections (draw ratio), and tension, ensuring product quality stability and consistency.

Sports, Fitness, and Safety Rope Extrusion Line Datasheet

Model	30	40	50	60	70	80	90
Screw Diameter (mm)	φ30	φ40	φ50	φ60	φ70	φ80	φ90
Screw L/D Ratio	25:1	25:1	26:1	26:1	26:1	26:1	26:1
Extrusion Amount (kg/hr)	25	40	70	100	140	200	250
Outlet Wire (mm)	0.2-1	0.4-3	0.8-5	1-8	2-15	3-25	5-35
Total Power (KW)	18	20	25	33	40	55	63
Traction Power (KW)	2.2	2.2	4	4	4	5.5	5.5
Production Speed (m/min (Max.))	600	600	600	500	500	300	300
Take-up Spool (mm)	φ200-400	φ300-500	φ400-630	φ400-630	φ500-630	φ800-1000	φ1000-1250

Sports, Fitness, and Safety Rope Extrusion Line Application

The high-performance ropes produced by this production line are widely used in fields with extremely high requirements for safety and reliability.
Sports and Fitness Field
Climbing Ropes & Mountaineering Ropes:
Requirements: Extremely high impact absorption capacity (low impact force), high breaking strength, excellent wear resistance, and flexibility.
Production Line Role: Produces core dynamic ropes that comply with UIAA (International Mountaineering and Climbing Federation) or EN standards. Typically employs precise multi-strand extrusion coating technology.
Sailing Ropes & Marine Lines:
Requirements: High strength, low elongation, corrosion resistance, UV resistance, smooth handle.
Production Line Role: Uses high-modulus polyester fibers and other materials to manufacture ropes capable of withstanding the immense forces from sails.
Tug-of-War Ropes:
Requirements: Extremely high static tensile strength, wear-resistant, anti-slip.
Production Line Role: Produces professional competition ropes with uniform diameter and sufficient strength to withstand tons of pulling force.
Others: Such as fitness resistance bands, tent guylines, golf bag straps, etc.
Safety Protection Field
Safety Ropes for Work at Height:
Requirements: Extremely high static load strength, wear resistance, cut resistance, clear markings.
Production Line Role: Produces braided or twisted safety ropes that comply with national mandatory standards (e.g., GB 24543-2009), used for fall protection for workers at height in industries like construction, power, and telecommunications.
Fire Rescue Lifelines:
Requirements: Flame retardant, high temperature resistance, high strength, lightweight.
Production Line Role: Uses special flame-retardant materials (e.g., aramid, high-strength polyester) to manufacture ropes for rescue and self-rescue in extreme environments like fires.
Rescue & Tow Ropes:
Requirements: High strength, good flexibility, easy to handle.
Production Line Role: Produces specialized ropes for scenarios such as vehicle recovery, water rescue, and earthquake rescue.
Industrial Sling Core Ropes:
Requirements: Serves as the load-bearing core inside webbing slings, requiring extremely high strength and very low elongation.
Production Line Role: Produces stable, high-performance polyester or nylon core ropes, which are later woven into flat webbing slings.