Transforming energy efficiency Sofilec

TRANSFORMING ENERGY EFFICIENCY

Sofilec is a European leader in the design and manufacture of electrical wires and cables for industrial manufacturing applications. Philip Yorke talked to Didier Balsat, the company’s general manager, about the significant benefits of its innovative HF Litz power cable systems and its move into new market segments.

Sofilec was founded in France in1986 by three entrepreneurs who decided to buy a company from the receiver that produced insulated electrical wire products. The company began with 25 people and saw consistent growth, so that by 2005 was in a position to buy out its main competitor: Buisin. This strategic acquisition had the effect of more than doubling the size of Sofilec and provided the company with a far more comprehensive portfolio of cable and wire products and services. The purchase also enabled it to offer copper and aluminium winding products for applications both inside and outside of large industrial transformers.

Today Sofilec has a turnover of over €60 million, employs over 170 people and offers a diverse range of cable and wire products and services. Its key customers are manufacturers of power and distribution transformers, traction transformers and big industrial electric motors and generators. Among its portfolio of blue-chip clients are giant global brands such as Siemens, GE, ABB, Alstom, CG Power and Brush. Sofilec operates two major production facilities in France, near Lyon, which supply more than 8000t of copper and 2000t of aluminium per year. The company’s principal markets have traditionally been western Europe, Middle East, North Africa, Eastern Europe. However, Asia and North America are becoming increasingly more important to Sofilec, especially for the company’s speciality wire products.

Custom-made solutions for every application

All Sofilec’s products are custom-made to meet the precise specifications of its global customers and none are standard off-theshelf designs. In addition, it offers an infinite variety of conducting and insulating material combinations. As an independent company, Sofilec is very flexible in its approach to achieving the best outcomes for its customers and can manufacture in both small and large quantities (from 50kg orders to 500 tons). This is in addition to offering dedicated component integration and tailor-made packaging services. Balsat says that Sofilec technicians are committed to finding the ideal solutions for its customers’ changing needs in today’s competitive marketplace.

From basic or assembled wires to shaped connections, Sofilec designs, manufactures and shapes its customers’ conductors while taking into account their thermal, dimensional, electrical and mechanical requirements. This can apply to energy transformers, instrument transformers, smoother-reactors and welding transformers. Furthermore, the company offers innovative solutions for PET-mica insulated conductors and insulated cables what-

ever the insulation system, whether it is VPI or Reach resin. In addition to its complete range of insulated conductors, Sofilec also offers a wide choice of HF LItz cable systems, which enable the customer to significantly reduce dielectric losses and optimise the performance of any coil winding system.

Pioneering new materials

Sofilec invests a significant proportion of its turnover in research and development at its two primary production plants near Lyon in France. There, a highly qualified team of experts are focussed on research into new insulating materials to enhance the efficiency of cables and to minimise power loss. Mr Balsat said, “Our customers need the best possible efficiency for their wires in order to significantly reduce power losses. With HF LItz, our customers gain by volume and weight and this new research is fundamental to the energy saving and eco-efficiency of the future that is important to us all. We are currently committed to developing the next generation of insulated products and enhanced raw materials. We bring the best solutions to market to minimise losses at a practical price level to help our customers achieve the best results, and to win market shares.

“We are also developing new insulation materials for the oil and gas industry and we work closely in partnership with our customers to help them to explore deeper, whilst at the same time improving weight ratios and saving space. We are leading the field in this area and helping our clients maximise their production potential in each location. In many instances we work as a co-manufacturing partner, which helps to achieve greater cost-efficiencies across the board thus saving our clients’ both time and money.”

Mr Balsat went on to say, “The future is definitely to be found in ‘high frequency (HF) Litz technology’ which is transforming the efficiency and performance of insulated cables. There are many possibilities in this area and we are pioneering new and effective solutions to enhance the efficiency of the equipment manufactured by our OEM clients and partners.”

Sofilec’s record-breaking components

Sofilec provides a diverse range of solutions for manufacturing industry’s insulated ‘shaped’ components. Whatever the application, Sofilec technology provides the best outcomes for its customers. From coated and creped Nomex to glass woven fabric and Micapaper, to Polymide film, nylon fibre and glass fabric tape, the company has the technology to meet any specification.

Recently ABB Secheron chose Sofilec products to participate in the TGV’s world speed record attempt, which resulted in a new speed record for France’s high-speed train. This futuristic train achieved speeds of up to 574.8 km/h. In another important commission, General Atomic (USA) chose Sofilec Litz cable for new military machine equipment. Sofilec was the only European manufacturer to fulfil 100 per cent specifications. n