Wire & Cable

Wire and cables plays an important part in our surrounding. A cable is two or more wires running side by side and bonded, twisted or braided together to form a single assembly. In mechanics cables, otherwise known as wire ropes, are used for lifting, hauling and towing or conveying force through tension. In electrical engineering cables used to carry electric currents. An optical cable contains one or more optical fibers in a protective jacket that supports the fibers.

Whether it is steel ropes ,cables, springs or screws, the products of the wire, cable and wire –processing industry are practically everywhere. They may look unassuming, but they are indispensable when it comes to the transmission of electric power or electronic data, and they assure that mechanical systems function well. The technological and economic development of a society is closely connected with the wire and cable industry and its suppliers. Since basically all areas of life rely on wire and the products that are manufactured from wire, and while their property potential is seemingly not yet exhausted, the wire, cable and wire processing industry is constantly faced with new challenges. In order to meeting these challenges it require machinery, tooling, accessories, ancillary equipment and services that are as efficient as possible in their utilization of energy and raw materials, and which produce as little waste as possible during startup and production.

Wires and cables sector basically consists of two areas: power and telecommunication. Power cables are PVC or PE clad, while the cables for telecommunication sector are based on PE (Polyethylene). Power cables are of 3 types depending on the intensity of power. Low-tension sector requires cables upto 1.1 KV and predominantly uses PVC insulation and jacketing. The medium tension power cables between 1.1 KV and 11 KV are based on PE as well as PVC. The high tension sector beyond 11 KV uses PE only. The low tension cables are used for tertiary distribution of power mainly from substations to buildings. Housing sector requires many other products for myriad applications. The medium tension cables generally use crosslinkable PE compounds while the high-tension cables use continuous vulcanization cables made from PE (LDPE). Electrical power cables used for transmission and distribution purposes consist of conductors stranded from plain high conductivity annealed copper wires insulated with oil impregnated paper tapes. Aluminium conductors have progressively come into use.

The market is divided into different segments in terms of product variation. The basic divi-sion is between cables and conductors. Cables are either power cables or control cables. Power cables supply energy at voltages upto 230 KV. Control cables are low voltage cables (upto 0.6 KV) used to transmit control signals in switch boards. The conducting material can be copper or aluminium with insulating material, PVC, XLPE, elastomers or paper. The cable market is segmented by the combination of material used to form the conductor, the insulator, sheathing and armouring.

Power cable industry in India is eyeing an estimated Rs 50 billion market to unfold. About 78,000 MW of power generation capacity and 60,000 circuit km of transmission network are projected to be added by 2012 according to the Eleventh Five Year Plan. Capex required for every MW of power generating capacity is about Rs 40 million. Expenditure required in the Eleventh Five Year Plan for power generation has been estimated at Rs 270 billion, besides Rs 69.5 billion for power transmission. Demand for cables should roughly be of the order of 3.5% of the investment in power generation and 2% for power transmission.

The expansion in output in the later years was basically an outcome of a spurt in industrial demand. High and low demand rates have characterised the industry for quite some time. During 2000-01 the production has been estimated at 30,000 km, about 18% lower than in the preceding year at 36,500 km. The 2000-01 level was only as high as that in 1993-94. The year 2003-04 witnessed a boom period with a very high growth rate. The demand was projected to grow from about 32,000 km in 2003-04, 38,000 km in 2006-07 and to 45,000 km in 2009-10.

The Indian power cable industry has about a dozen producers in the organised sector, claiming more than two-thirds share of the market. The unorganised sector is constituted of a few small units. The divergence in the two segments goes beyond their unit sizes. The two sectors exhibit significant differences in quality and the capacities. While the organised sector has been manu-facturing high voltage and speciality cables, the unorganised sector limits itself to the relatively low voltage market. The organised segment caters also to the industrial market.

The State Electricity Boards remain the major buyers for power cables. Small buyers of power cables also include companies having their own power distribution within plant limits. Conforming to their need-patterns, they require low tension PVC and medium tension XLPE cables. It is obvious that the client profile is changing from what it was. The thrust has slowly shifted to private sector and exports.

Private power generation companies like BSES, with expansion plans underway, are generating significant demand. Nonetheless, for the time being the State Electricity Boards continue to be the big customers. The major players in the organised industry are: Cable Corporation of India, Universal Cables, Fort Gloster, Industrial Cables, Uniflex Cables, RPG Cables, Finolex Cables, Paramount and Hindustan Vidyut Products.

Moreover, the global renewable energy industry is very well suitable for a boost of the cable industry. The upcoming challenges will be offshore installations with special tower cables in the renewable energy sector in the coming years.

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COPPER WIRE DRAWING (From Higher Size To Very Thin Size Used In Electrical Cables)

Copper wire is an essential material for electrical cables and motor and transformer winding. Copper wire is available in different gauges (42 gauges to 18 gauges). The gauge of the copper wire depends upon the winding required for the specific motor or transformer. There is a heavy market for copper wire in motor and transformer manufacture and the copper is also used in rewinding of motors and transformers. Whatever the motor may be the winding of copper wire is done. On the basis of high conductivity, strength and ductility, copper wires are adopted as the best known economical material for such purposes. Copper is used mainly in the electrical industry for manufacturing parts of electrical apparatus, bus bars, wire etc. Copper is not very ductile at temperature from 250 to 6000C and cannot be forged or stamped at temperatures above 8000C, due to its high brittleness. Pure copper is very seldom forged or stamped and usually only its alloys bronze and brass are subjected to forging and pressing. Wire is made by cold drawing hot-rolled wire/rod through one or more dies, to decrease its size and increase the physical properties. The wire rod about 7/32" (6mm) in diameter is rolled from a single billet and cleaned in an acid bath to remove scale rust and coating. The coating is applied to prevent oxidation, neutralize any remaining acid and to act as a lubricant or a coasting to which a later applied lubricant may cling. There is a very good scope for this product and new entrepreneurs should venture into this field. Few Indian Major Players are as under: Metal Aids India, Mumbai Nissan Copper Limited Samitan Electropowers (P) Limited S. M. Enterprises, New Delhi Niki Cables Industries Bharat Insulation Company (India) Ltd Elecon Conductors Limited Saru Concast Alloys Pvt. Ltd. GTB Indo Exports Shree Nursingsahay Mudungopal Engineers Private Limited Metro Steel Corporation Optiflex Industries Nana Udyog Saru Copper Alloy Semis (P) Ltd. Manhar Metal Supply Corporation Harness Techniques(i) Pvt Ltd National Wire Industries Metal Aids India Indo German Wire Screen Co. A. P. S. Enterprises Oasis Electronics Max Engineering and Marketing Company KMA Electricals (P) Ltd. Sharpwire Industries (India) Private Limited Kawa Machine Tools Sdn Bhd Dali Electronics Vijay Trading Corporation
Plant capacity: 150 MT/AnnumPlant & machinery: 69 Lakhs
Working capital: -T.C.I: 167 Lakhs
Return: 45.00%Break even: 42.00%
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POWER CABLE

The Power cable is the key element of new generation Power distribution network. Wire and cables plays an important part in our surrounding. A cable is two or more wires running side by side and bonded, twisted or braided together to form a single assembly. In mechanics cables, otherwise known as wire ropes, are used for lifting, hauling and towing or conveying force through tension. In electrical engineering cables used to carry electric currents. An optical cable contains one or more optical fibers in a protective jacket that supports the fibers. Essential power cables used for transmission and distribution purposes consist of conductors stranded from plain high conductively annealed copper wires insulated with oil-impregnated paper tapes. The single or multicores assemble in them enclosed in an impermeable metal sheath, and where necessary depending on installation conditions, the assembly is protected by steel armoring. Modern cable technology is still pursuing the above ideal, but today many other additional factors have also to be considered, as indicated in the following notes (dealing with oil impregnated paper insulated cables), which are divided into three main parts, the first dealing with cable design, the second part outlines modern manufacturing methods and the third section discusses installation requirements. To the electrical industry faced with the continuing and probably inevitable increase in the cost of copper, the economic factor has necessarily been of vital importance. The Indian Cable Industry already has Co-operated readily with Government and the electric power industry in the country in producing aluminium- conductor insulated power cables. They have also established elaborate training facilities for wiremen and electricians in the jointing and installation of aluminium cables. The switch-over to aluminium for power and house-wiring cables in India has been dictated mainly from the point of view of availability and the difficult foreign exchange situation now prevailing. However, when free market conditions resume and when copper becomes freely available either from imports or by exploitation of indigenous copper ore reserves, the cable industry expects that a fair share or such copper will be allocated to it and the electric power industry in adequate quantities so that copper or aluminium could be used in cables to suit customer preference, technical requirements and real economics. The selection process of power cables is almost the same as that of a bus system. The basic data for selection would suffice the majority of applications. For site conditions and lying arrangements, which may influence the basic rating of a cable, corresponding daerating factors is also indicated. The information covered for the users to select their cable requirements. PVC coated cables and wires are extensively used in all electrical linings, domestic lightings and all other purposes. Parkway lighting, river crossings, and lighting of the grounds of an institution are among the more common applications of armoured cable. According to the present policy of the India Government, this time, PVC coating on electric cables and wire is exclusively reserved for development in small scale sector or in the cottage industries. Power cables play a small but significant part in infrastructure activities. With strong investments proposed across sectors such as power, realty, industrial and telecom, the cable industry in India is slated for a strong growth going forward. In India, the underground electricity distribution networks are rapidly undergoing upgrades to meet the growing requirements of quality power for industrial and residential use. There are also increasing trends of converting the overhead line to underground cables in low tension (LT) & high tension (HT) network in urban distribution networks. The demand for PVC coated electrical wires (with the rapid electrification all over the country) is increasing at a rapid rate. Hence there is a bright scope for starting new units in this field. Few Indian Major Players are as under: Asian Cables & Inds. Ltd. Cable Corpn. Of India Ltd. Central Cables Ltd. Chandresh Cables Ltd. Cords Cable Inds. Ltd. Delton Cables Ltd. Emgee Cables & Communications Ltd. Gateway Systems (India) Ltd. Havells India Ltd. Hindusthan Vidyut Products Ltd. I L A C Ltd. Incab Industries Ltd. Moti Electric Industries Ltd. Paragon Power Cable Ltd. Polycab Wires Pvt. Ltd. Power Infotech Ltd. Ravin Cables Ltd. Vora Wires Inds. (India) Ltd.
Plant capacity: 2050 MT/Annum Aluminium Power Cable,350 MT/Annum Copper Power CablePlant & machinery: 95 Lakhs
Working capital: -T.C.I: Cost of Project : 357 Lakhs
Return: 45.00%Break even: 63.00%
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PVC Wires and Cables

Profile PVC copper wires are used extensively in making power transformers, panel boards, electric motors, etc. PVC (polyvinyl chloride) is a versatile thermoplastic material obtained from ethylene (petro chemistry product) and salt by vinyl chloride polymerization. The cables are suitable for use on AC single phase or three phase (earthed or unearthed) systems for rated voltage up to and including 1100 volts. These cables can be used on DC systems for rated voltage up to and including 1500 volts to earth. Types of PVC cables are: • PVC insulated entwined wires used for service connections • Twin twisted PVC insulated wire for appliances • Flat type PVC cord having two parallel PVC insulated wires for appliances • Round type PVC cord having twin twisted PVC coated wire sheathed with round PVC sheathing • PVC insulated over head wire consisting of 20 to 30 core wires about 0.5 mm. dia., twisted together and covered with PVC • PVC insulated control cable for appliances, low voltage distribution, telephone wire, switch board wiring, and cables for automobiles. Application • PVC wires & cables are used in home appliance, house wiring, T.V, VCR control pannel, power distribution & secondary transmissions etc. The main use of PVC wires & cables are in house wiring. Since as the name suggests it’s used everywhere, where electricity is to be carried from one point to another with safety. • Domestic cables & wires used extensively. These types of cable are used in house wiring, wiring of T.V, Video & Control panel circuits. These types of wires are used where temporary wiring for domestic use is necessary. • Power cables are used mostly by electricity boards & big industries where consumption of electricity is large. These cables are used for domestic supply of electricity in big towns of cities or in workshops . ? Market Potential PVC is one of the most used plastic materials in the world. At global level, demand for PVC exceeds 35 million tonnes per annum and it is in constant growth (+5% on global average), with higher growth rates in the developing countries. In the funding scenario & with the overall economic scenario gaining accelerated momentum, robust growth over the next few years across the cable industry in India is expected. It is estimated that there are around 1,000 cable making companies across the world. Demand is stimulated by major electrification programmes to extend energy networks.
Plant capacity: 3992 Coils/ Day Plant & machinery: 234 Lakh
Working capital: -T.C.I: 4481 Lakh
Return: 70.00%Break even: 18.00%
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Information
  • One Lac / Lakh / Lakhs is equivalent to one hundred thousand (100,000)
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  • T.C.I is Total Capital Investment
  • We can modify the project capacity and project cost as per your requirement.
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