pvc cables manufacturing process

How to Start PVC Cables Manufacturing Business

Do you want to start PVC Cables manufacturing business? If yes, you are in the right place.

A cable comprises two or more wires which are bonded, twisted, or braided together to form an assembly. The wires and cables are encapsulated with non-conducting plastic materials, usually, PVC or polyethylene, to impart protection to users and the surrounding environment.

PVC cables are major equipment for the transmission & distribution of electrical power. They are suitable for use in substations, distribution systems, Industrial installations, house wiring, and street lighting. PVC-insulated wires and cables work as a medium for the distribution of electricity. The PVC cables manufacturing process is simple. The business can be initiated on a small and medium scale basis.

Is PVC Cables Manufacturing Business Profitable?

The electric wire and PVC cable market are expected to grow in the coming years. The demand for domestic electric cable will increase first. This is due to an ambitious program for electrification and house building.

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It is also due to the renovation job as the old cable has to be removed to avoid any short circuit due to aging with the new advanced cable of high conductivity in a given size with perfect insulation against any electric fault. Some of the bulk purchasers of this product are coal fields & collieries, Electricity Boards, Railways, All types of Power Stations, the Aviation industry, and Housing Boards/Colonisers.

10 Steps to Start PVC Cables Manufacturing Business Business

1. Do market research

Before starting any business, it is important to do market research to understand the demand for a product. The same is true in the PVC cables business. Identify your target market and find out what types of PVC cables are used in your area. Also, check out pricing, and their distribution network.

2. Create a Business Plan

Once you have a clear understanding of your target market, create a detailed business plan. The plan document must explain in detail your manufacturing process, marketing strategy, financial projections, and management structure. This business not only works as a roadmap but also is a mandatory document for availing of business loans.

3. Registration & License For PVC Cables Manufacturing

In starting PVC cable manufacturing, register your business with ROC. Obtain Trade License from Municipal Authority. Apply for GST Registration. Protect your brand name with Trademark registration. Apply for Udyog Aadhaar MSME Registration.

Additionally, obtain BIS Certification. This is a pollution-free manufacturing operation. However, waste minimization of PVC compound to strictly adhere to. Apply for a ‘No Objection Certificate’ from your state Pollution Control Board.

Read: How to Register a Company/ Startup in India

ETDC, ER TL, R TC, Electrical Research & Development Association Vadodara is the major development & testing center for this product. Entrepreneurs venturing into the field of PVC cable manufacturing can seek help for testing their products.

4. PVC Cables Manufacturing Machine & Testing Equipment

  • PVC Extruder and Wire Coating Machine 50 mm complete with cooling through supply stand take up the unit control panel with Automatic Temperature
    indicator controller and electrical motors.
  • Wire Straightening equipment
  • Cable Printing Machine
  • Measuring & Coiling Machine
  • Extrusion Dies, NOZZLES, etc.
  • Spark Tester
  • Vernier Micrometer
  • Travelling Microscope 0.100 mm least count 0.001 magnification 10X
  • Chemical Balance 0.200 gm Least measure 0.1 mg
  • Kalvin’s Double Bridge
  • Tensile testing machine
  • Electrically heater thermostatically controlled Air-cooled Oven
  • Pressure test apparatus (for Hot deformation)
  • High Voltage test set AC (0 to 10 KV)

5. Raw Materials For PVC Cables Manufacturing

The required raw materials are E.C. Grade Aluminium Wire, PVC Compound (Cable Grade), and packaging consumables. The raw materials can be procured either from a wholesale market or from the manufacturer of the said items.

6. PVC Cables Manufacturing Process

A copper conductor (wire) of the required size is fed into the Extruder wherein PVC is coated on the wire to the specified thickness. The extruded wire after passing through the cooling tank is coiled on the take-off system. The wire is coiled into a length of 100 meters and tested as per IS specifications.

Insulation is strict as per National and International specifications. PVC cables are available as Thermoplastic dielectric. PVC cables use a PVC compound that takes care of overload and short circuit currents with both coarse and fire protection systems.
Laying up: Cores are tested on the line during production both for the physical and electric characteristics. For multi-core cables, cores are laid upon the latest laying machine, equipped with sector correction equipment.

Laid-up cables are provided with insulation of high-quality PVC polymer which is softer than the outer sheath and is compatible with the temperature rating of the cables. Cables are provided with PVC/polymer outer sheaths with various characteristics of sheathing compounds.

The final step is testing. Cables are undergone the following tests:

  • Conductor resistant test
  • The thickness of thermoplastic and elastomeric insulation and sheath
  • Tensile strength and elongation at break of thermoplastic and elastomeric insulation and sheath.
  • Thermal aging in the air.
  • Shrinkage Test.
  • Ozone-resistant Test
  • Heat shock Test.
  • Hot deformation Test.
  • Bleeding Test.
  • Cold impact Test.
  • Water absorption test (electrical)
  • Environmental stress cracking test

7. Quality Control & Standards

The Bureau of Indian Standards has laid down specifications:

  • IS: 694 – 1977 PVC insulated cables for working voltage up to and including 100 volts (second revision)
  • IS:: 5831 – 1970 PVC insulation & sheath of Electric Cables?
  • IS 8130 – 1976 Conductors for insulated Electric Cables and flexible coils.

ISO 9000 defines standards for Quality Management systems and ISO 14001 defines standards for Environmental Management systems for acceptability at the international level. You can adopt these standards for the export potential of the PVC cables manufacturing business.

8. Arrange Funds

Starting and running a PVC cables manufacturing business requires a good amount of capital investment. If you are short in budget, there will be a need to secure financing from banks, investors, or lenders.

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9. Hire Manpower

Hire skilled workers who have experience in cable manufacturing. Provide comprehensive training to ensure that they understand the manufacturing process and can produce high-quality cables.

10. Develop a Marketing Plan

Create a marketing plan so that you can reach your customers by spending less money. Do not forget to create a website as having an online presence is mandatory nowadays for any business to be successful.