Problem Case Description:

PT. Prysmian Cable Indonesia has a problem of safety working in their Lead Extruder area due to its thermal exposure to the environment. It is a machine that has a purpose for melting lead in order to be used as one of the cable components. In the process of melting and extruding the lead, it needs constant heat from element/ heater at around 375oC. Even though this machine has already completed with Rockwool insulation with 25 cm thickness, the high temperature still appears at the surface at around 90oC – 147oC.

This high temperature creates unsafe working areas due to the risk of getting touch by workers as well as affecting uncomfortable conditions to work.

Proposed Solution:

Considering the core issue and the needs of PT. Prysmian Cable Indonesia to create a safe working area at Lead Extruder, PT. Mahita Karya Persada Teknik (MKPT) Coating and Insulation Division proposed to use Hot Pipe Coating (HPC). It is a ceramic-based coating that has the purpose to block heat transfer from inside the machine to the environment.

Hot Pipe Coating (HPC) is applied by spray method so it can conform to any kind of profile and surface of the Lead Extruder machine. It is water-based coating with special resin so it can be applied directly to the metal surface of Lead Extruder after being cleaned.

As the concern issue is a safe working area, Hot Pipe Coating (HPC) is applied at a minimum of 12.5 mm DFT. We expect to create finish temperature at 60oC which already comply to ASTM ‘five-second’ safe to touch rules.

Rust Grip is then applied as a finished coating for protection from outer contaminant it may have a risk of being contaminated by liquid lead when the machine operates.


After Hot Pipe Coating (HPC) application, the finish temperature appears at around 60oC with 13-18 mm DFT and already creates a safe working area near the machine.