pvc cables manufacturing process

How to Start PVC Cables Manufacturing Business

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, street lighting. PVC insulated wires and cables are the ultimate medium for the distribution of electricity. PVC cables manufacturing process is simple. The business can be initiated on a small and medium scale basis.

PVC Cables Manufacturing – Market Potential

Electric wire and PVC cable market in India to grow at a CAGR of 16.18% over the period 2015-2019. The demand for domestic electric cable will increase firstly. This is due to an ambitious program for electrification and house building.

It also due to renovation job as old cable has to be removed to avoid any short circuit due to aging with the new advanced cable of high conductivity in 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.

Related: Profitable Home Based Manufacturing Business Ideas

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. 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 in the field of PVC cable manufacturing can seek any help for testing their products.

PVC Cables Manufacturing Machine & Testing Equipment

  1. 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.
  2. Wire Straightening equipment
  3. Cable Printing Machine
  4. Measuring & Coiling Machine
  5. Extrusion Dies, NOZZLES, etc.
  6. Spark Tester
  7. Vernier Micrometer
  8. Travelling Microscope 0.100 mm least count 0.001 magnification 10X
  9. Chemical Balance 0.200 gm Least measure 0.1 mg
  10. Kalvin’s Double Bridge
  11. Tensile testing machine
  12. Electrically heater thermostatically controlled Air-cooled Oven
  13. Pressure test apparatus (for Hot deformation)
  14. High Voltage test set AC (0 to 10 KV)

Raw Material 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.

PVC Cables Manufacturing Process

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 the length of 100 meters and tested as per IS specification.

Insulation is strict as per National and International specifications. PVC cables are available as a 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 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:

  1. Conductor resistant test
  2. The thickness of thermoplastic and elastomeric insulation and sheath
  3. Tensile strength and elongation at break of thermoplastic and elastomeric insulation and sheath.
  4. Thermal aging in the air.
  5. Shrinkage Test.
  6. Ozone-resistant Test
  7. Heat shock Test.
  8. Hot deformation Test.
  9. Bleeding Test.
  10. Cold impact Test.
  11. Water absorption test (electrical)
  12. Environmental stress cracking test

Quality Control & Standards For PVC Cables Manufacturing

The Bureau of Indian Standard has laid down specifications:

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

The 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.