Wire & Cable India Emagazine Jan-Feb Issue 2021

CONTENTS January-February, 2021, Wire & Cable India

NEC Wire & Cables: All-Geared Up for the Future

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“The company has made significant investments in its manufacturing infrastructure in the last few years; and in 2020, it has installed high profile configuration machinery at its wires and cables manufacturing plant in Greater Noida…”

08 16 E-Beam Wires and Cables: Scope & Prospects In the past few years, there’s been a gradual build up in the demand for electron beam processing in wires and cables. In view of the rising prevalence of the processing technique, team Wire & Cable India has initiated an editorial feature to present an insightful article on the know-how of the technique, the outlook of the prominent players in the wire and cable sector...

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Polycab’s DNA: EXPANSION TURNOVER GROWTH

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“Polycab is the market-leader in the wire and cable segment in India, with more than 18% of the overall market-share. Despite being a relatively new entrant in the telecom industry, we achieved an impressive growth in OFC-sales in FY 2019-20.” – Mr. Ashish D. Jain

Kemtree: Striding Ahead With Renewed Vigour and Vision

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“As we move forward, we understand that branding plays an especially important role in today’s business world and we believe that KEMTREE will certainly become a strong brand in the coming times.”

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Union Budget 2021: Wire & Cable Industry View

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Finance Minister Nirmala Sitharaman presented her third Budget — Union Budget 2021. Several key industry leaders share their view and feedback. Here is a compilation.

50 Leebo Metals: Aspiring to Expand Capacity & Market Footprint

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“While maintaining an exorbitant pace of growth, one of the main goals for the next two years is to install and achieve a target of about 40000 MTPA by 2023. In addition, we plan to increase the customer base to reach more than 1000 active customers, and aspire to be the undisputed leader in quality metal supply” - Mr. Rajesh Agarwal

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HPL Electric and Power: Post-Pandemic Reality is a Whole New Ball Game

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Maillefer Extrusion: Prioritizing Local Manufacturing in India

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FUTURE READY

Polycab’s DNA:

EXPANSION

TURNOVER

GROWTH “Polycab is the market-leader in the wire and cable segment in India, with more than 18% of the overall market-share. Despite being a relatively new entrant in the telecom industry, we achieved an impressive growth in OFC-sales in FY 2019-20.” – Mr. Ashish D. Jain Involved in manufacturing optical fibre cables since 1998, today, Polycab India has a state-of-the-art manufacturing facility and an independent business-vertical for OFCs, FRP/ARP Rods, IGFR Yarns and Communication Cables at Halol in Gujarat. Polycab’s Telecom Division has been working for BharatNet project as a Project Implementing Agency (PIA) and now, it has introduced end-to-end passive networking products with a comprehensive host of accessories.

In an interview with Wire & Cable India, Mr. Ashish D. Jain, Executive President & COO, Telecom Division, Polycab India Ltd. sheds light on the business story of the Company, the market presence, the company’s growth strategies including their capacity expansions, the outlook on ‘BharatNet’ initiative, and the key steps to make India a global hub for OFC-production in line with the ‘Aatmanirbhar Bharat’ mission.

Wire & Cable India: Could you please present a brief overview of the business-story of the telecom division of Polycab India Ltd.?

Ashish D. Jain: Polycab India Ltd. is one of the most recognized and trusted Indian names, with leading

Mr. Ashish D. Jain

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Jan-Feb, 2021

FUTURE READY

Manufacturing Unit at Halol for OFCs, FRP/ARP Rods, IGFR Yarns and Communication Cables

WCI: In view of the futuristic technologies such as 5G, AI and IoT-applications, and considering the major developments in 2021, 4G spectrum auctions and upcoming 5G-launch, how do you think these will influence the growth of the telecom sector infrastructure?

market position in wire & cable and FMEG segments.

As connectivity undergoes evolutionary changes in most parts of the world and ‘digital data’ becomes the new currency of our networked future, we’ve made a strong foray into the telecom domain, responding to the emerging times and opportunities.

ADJ: Futuristic technologies and especially 5G, as a next-generation wireless technology, would definitely create requirements of low latency and ultra high speed data rate. Further, the widespread use of digital services would generate huge data traffic and connection density.

And all of these would require a rapid and structured optical fibre roll-out at massive scale in India, which subsequently would provide tailwinds to our sector.

We’ve traversed a remarkable journey of more than five decades of proven expertise and experience in cable manufacturing, which makes us uniquely positioned to manufacture and craft a whole range of end-to-end passive networking products and accessories for voice, data and video applications of communication networks.

Of course, passive networking has two facets, first, creation of the new passive networking infrastructure and second, up-scaling of the existing ones. We’ve built capabilities at both the levels, to have strong business potential for ourselves.

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As far as increasing the fibre-based network is concerned, regulatory policies, investments and infrastructure readiness will play a key role. In addition, an integrated RoW-policy would go a long way to bring in the required speed for smooth fibre roll-out.

With a dedicated manufacturing set-up of data networking products and accessories, comprising copper cables and optical fibre cables, and capability to execute end-to-end network roll-out, the business story of the telecom division of Polycab signifies the core vision of a smarter world.

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FUTURE READY WCI: Would you mind sharing details about India’s total fibre footprint, as compared to the global average and the ways in which the fibre growth is being driven here? Also, how do you relate Polycab’s role in this growth story of telecom infrastructure?

Several ongoing projects like BharatNet, FTTH, 4G and 5G-rollout would create a huge demand for OFCs in the coming future. Moreover, the new work-from-home culture has created necessary and enormous demands for bandwidth-requirements with quality services from the telecom industry. Ensuing demands for OFCs and passive infrastructure would surely expand the optical fibre cable market in the country.

ADJ: India’s per capita fibre-coverage is 0.09 km, against 0.87 for China and more than 1.3 for the United States and Japan, as per an ICRA Research Report. As far as increasing the fibre-based network is concerned, regulatory policies, investments and infrastructure readiness will play a key role.

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The next five years would be as promising, as we have been working for BharatNet projects as a Project Implementing Agency (PIA).

In addition, an integrated RoW-policy would go a long way to bring in the required speed for smooth fibre rollout. Fibre-first initiative with incentives and promotion for fibre connectivity in new residential and commercial developments should lead the way in response to the impending 5G-deployments. Our government has recently approved enlistment of telecom equipment manufacturing for the PLI-scheme, which would definitely motivate and boost the ‘Make in India’ model in the sector. The fibre deployment in the country will need to increase 2-3-fold from current market of 16-18 million fkm per year to realistically match up the global average.

The government has also intensified its efforts to fasttrack ambitious projects like BharatNet and fiberization of each telecom tower to facilitate fibre connectivity for each household. Polycab has deep expertise in manufacturing OFCs and has successfully executed endto-end network roll-outs.

ADJ: Polycab is the market-leader in the wire-and-cable segment in India, with more than 18% of the overall market-share. Despite being a relatively new entrant in the telecom industry, we achieved an impressive growth in OFC-sales in FY 2019-20.

The next five years would be as promising, as we have been working for BharatNet project as a Project Implementing Agency (PIA). Further, building on our strength of OFCs and data cables, we would be launching end-to-end passive networking solutions with a whole host of accessories. With a single OEMstrategy for electrical and passive networking solutions and accessories to get all its products under one brand, Polycab creates strong national sentiment and aligns perfectly with the essence of Indian government initiatives like ‘Make in India’ and ‘Aatmanirbhar Bharat’. Riding on the trust and brand value of competitive products at affordable prices, our telecom division is certainly headed for healthy growth over the next five years.

WCI: Kindly outline the different markets you serve and your plans for further expansion to different geographies!

What are your views on the potential of the Indian telecom and optical-fibre-cable market?

ADJ: As our government, under the dynamic leadership of Shri Narendra Modi, has made a clarion call for Aatmanirbhar Bharat to make our country play a bigger role in the global economy, Polycab is uniquely positioned in providing end-to-end data and powersolutions in different markets across geographies.

Secondly, Polycab has a strong national presence with a large network of partners and consortiums to work on various projects.

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Speaking of technological expansions, we can say that they are integral in our mechanism, as an ongoing process. We’ve already expanded the factory-production capacity by three times, from the time we started our journey and have been doing so in the lockdown-period as well, particularly in the OFC-segment.

Several ongoing projects like BharatNet, FTTH, 4G and 5G-rollout would create a huge demand for OFCs in the coming future.

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WCI: Could you please share some details about the Polycab’s performance and growth registered in the previous year in the telecom-segment? How do you envision the next five years for the company’s growth?

Also, has there been any or do you plan to make any investments for capacity-expansion or technological upgradations for the OFC-segment?

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Jan-Feb, 2021

FUTURE READY

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Polycab, with its consortium partners, has already demonstrated its end-to-end network roll-out capabilities in Bihar and Gujarat. Moreover, we are actively exploring several other opportunities. With our strong manufacturing capabilities for data and power-solutions and proven knowhow for high-speed network roll-out, we are proactively contributing towards ‘Digital India’ journey.

We’ve already expanded the factory-production capacity by three times, from the time we started our journey… particularly in the OFC-segment.

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WCI: What could be the key steps that could pave the way to make India a global hub for OFC-production and supply and support the country’s ‘Aatmanirbhar Bharat’ mission in the sector?

WCI: How pertinent do you deem national initiatives like ‘Digital India’ and ‘NOFN’ for surging the scope of OFC-demand in the country in general, and the growth of your telecom cable business in particular?

ADJ: India can very well emerge as a global hub for OFC production. If OFC manufacturing also gets included in the recently announced PLI scheme of the government, a new wave of technological advancements and investments would propel the sector to a higher level altogether. Additionally, an ecosystem of innovations, cost-competitiveness and ease of doing business in OFC manufacturing would certainly support missions like ‘Aatmanirbhar Bharat’ in the sector.

ADJ: OFCs have always been the real spine for highspeed digital infrastructure. And a digital infrastructure, which enables high speed in the data flow and makes the networks meet the standards of desired performance and longevity, is the bedrock to realize the aims of ambitious initiatives like Digital India and NOFN, which was renamed later as BharatNet. So, as these initiatives gain momentum, the demand of the OFCs will augment further in all the corners in our country.

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Jan-Feb, 2021

E-BEAM

E-Beam Wires and Cables: Scope & Prospects History of E-Beam

In the past few years, there’s been a gradual build up in the demand for electron beam processing in wires and cables. In view of the rising prevalence of the processing technique, team Wire & Cable India has initiated an editorial feature to present an insightful article on the know-how of the technique, the outlook of the prominent players in the wire and cable sector – Polycab, Thermo Cables, Anand International, Apar Industries, and Vindhya Telelinks on this advancement, and the various advantages that E-beam offers as compared to the conventional curing processes.

The history of electron beam technology can be traced back to the year 1869 with the experiments by physicists Hittorf and Crookes who first tried to generate cathode rays in gases. These cathode rays were an interesting physical phenomenon and this led to the discovery of a particular type of ray by Roentgen (1895), Thompson (1897) and Millikan (1905), which were described as “fast moving electrons”. However, at that time, the heat generated by the impact of the electrons was considered rather to have a damaging effect in those experiments and attempts were made to prevent this by means of cooling. In the following time, more and more scientists experimented with electron beam technology, which led to the development of oscillographs, microscopes and the drilling of metals.

Electron beam (E-beam) processing is a technology that has a diverse range of commercial, medical and industrial applications. It provides an effective and efficient means to give rise to favorable changes in the properties and the performance of polymers and a range of other materials. The technology is also widely used for the sterilization of medical devices, pharmaceuticals and cosmetics.

In 1948, a new era in material processing began with the physicist Dr. h.c. Karl-Heinz Steigerwald who was working on the further development of electron beam sources with higher powers for the construction of electron microscopes. The year 1952 is regarded as ‘the dawn of electron beam technology’ when he built the first electron beam processing machine.

In the wire and cable industry, E-beam irradiation provides enhanced cross-linking and polymer modification for wire, cable, and tubing products. The processing technique, more often than not, doesn’t require any additives, nor does it generate any hazardous chemical by-products. In addition, the E-beam crosslinking does not require the hours of cure time needed for other conventional chemical cross-linking methods. This is an energy-efficient process, and the minimal amount of exposure time helps ensure high throughputs.

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In recent years, the electron beam processing is now getting widely used for medical and industrial applications. Also, with a series of advancements made in this technology, electron beam accelerators are regarded as reliable and durable equipment that can produce ionizing radiation for a number of applications.

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Jan-Feb, 2021

E-BEAM On the industrial scale, accelerators are used to generate electrons in between 0.1-100 MeV energy range. These accelerators are used mainly in plastics, automotive, wire and electric cables, semiconductors, healthcare, aerospace and environmental industries, as well as numerous researches.

Cross-linking of Wires and Cables with E-Beam Electron beam cross-linking of wire insulation and cable jackets is usually done with electron energies in the range from 500 keV to 1.5 MeV, although some facilities use higher energies up to 3 MeV. The energy is determined by the thickness, density and atomic composition of the insulation and the diameter of the conductor. The processing technique is highly precise as the stability of the small electron beam diameter in the focus is the basis for high geometrical precision.

Elaborating on the gradual demand shift, the growing potential of the E-Beam wires and cables and their role, Mr. N Srinivasa Rao, President, Thermo Cables Limited says that “with an estimated potential of Rs. 2,000 crore per year in the domestic market for E-beam wires and cables, we would like to have as much share as possible from this consistently rising demand. We are educating our customers about the advantages of the E-beam cables over conventional cables.”

Benefits of E-beam Processing E-beam cross-linking protects wire and cable insulation from the heat of short-circuits as a result of hightemperatures. The processing improves a range of properties of Electron Beam Cross-Linked (EBXL) wires and cables such as – tensile strength, especially at elevated temperatures, abrasion-resistance, thermalresistance, flame-propagation-resistance, deformationresistance, and cut through-resistance. Moreover, it also increases the shear and compressive strength of the wires and cables.

Emphasizing upon the numerous benefits of the E-Beam processing technique, Mr. K R Chandrasekhar, Executive V.P., Polycab India Limited, says: “the E-beam curing process has a number of advantages over other conventional curing processes including the fact that it is an eco-friendly and green process causing zero environmental pollution.”

Time is not far when EBXL wires and cables will be soon replacing the normal cables in key strategic applications – in fact, the process has already begun with various companies offering E-beam cables for the past few years.

However, the market for e-beam cables in India is yet to achieve a considerable benchmark and fulfill the industry’s expectations.

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Jan-Feb, 2021

E-BEAM

LEONI Cable Solutions: E-Beam Processing Yields Symmetrical Results and Enhances Various Properties of Wires and Cables

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he e-Beam processing in wires and cables helps in improving thermal, insulation resistance, di-electric property, chemical resistance property, barrier, impact wear and other mechanical properties…

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Excerpts of the interview with Mr. Sandesh Bhagwat, Managing Director at LEONI Cable Solutions (India) Private Limited: Product Portfolio and Technical Capabilities

LEONI Cable Solutions is a world leader in the e-beam radiated cables. The superior technology and process leadership was introduced in India by LEONI in 2018.

The Company has state-of-the-art e-Beam equipment which is crossfire of 2x1.5 MeV, with 2 accelerator tubes. This provides uniform radiation in 360 deg in the products. LEONI has been certified by Indian and international testing companies for the products including – single-core and multi-core cables for transportation industry with several approvals like RDSO, EDTS, CLW, and Metro OEM’s; and single-core solar cables with EN design with TUV approval.

Mentioning the numerous technical advantages of the Electron Beam Cross-linked (EBXL) cables, they provide higher current carrying capacity, greater safety margins and have an improved integrity in case of electrical failures. They also display an improved resistance to chemicals, has better impact strength and crack resistance and further, they also have better weather and high abrasion resistance. Also, the cables are infusible, and have resistance to iron soldering.

Mr. Sandesh Bhagwat

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E-BEAM As about the other advantages, the EBXL cables have a long service life, high resistance to media (oils, fuels, acids and alkalis), UV and ozone, and have the ability to operate under extreme conditions (–60 °C and +120 °C). The cables are halogen-free, flexible, have optimized weight and volume, and high resistance against cold, heat, oil, diesel, acid and alkaline.

Manufacturing and Technical Setup With respect to the technological capabilities and our manufacturing setup for the production of EBXL wires and cables, we have the Hybrid CrossFire Technology (2x1.5 MeV 60mA), i.e. a sophisticated new generation e-Beam equipment. Homogenous cross linking is made possible because of 90˚X4 irradiation and there is a fourside treatment during the irradiation process.

partner, we assist our customers during the projectplanning phase and thus, we’re able to generate an added value by finding solutions which are exactly adjusted to their individual needs.

With our business unit transportation, and rolling stock division, we provide our customers with all the expertise of a global enterprise, focused on the needs of the transportation industry. With our extensive product and service portfolio for the internal and external cabling of rolling stock, we accompany the entire life cycle of vehicles – worldwide.

We have a patented technology for insulated core high voltage transformers; and there is a unique design to cater to a wide range of products. The e-Beam process further ensures equal dose distribution, high speed, and with online data logging, it is fully synchronized. The facility has a 2-cable handling system available in a single machine and we can operate one or both the accelerators at the same time. Further, the inbuilt safety system is AERB-approved.

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s a strong and reliable partner, we offer application-specific cables and cable system solutions according to the national and international standards.

No area requires access restriction except the bunker which is highly secured with the state-of-the-art safety system. There is a double security system (fail-safe) that is made as per Cat 4, EN 954-1. It honors the autocontrol and redundancy requirements. The complete bunker is entirely shielded with high-grade reinforced steel which confines the process and protects the surrounding area from energetic electrons. In addition, there is an ozone extraction system with filtering and online monitoring.

As a strong and reliable partner, we offer applicationspecific cables and cable system solutions according to the national and international standards. In the process, our customers can rely on our well-established industry, product knowledge, and our long-time experience.

With the extensive product and service portfolio for internal and external wiring of railway vehicles, we will accompany you throughout the entire life cycle of your vehicles.

Market Footprint LEONI Cable Solutions is a worldwide leading provider of standard and customized specialist cables as well as prefabricated cable systems.

Value added chain of products and services from LEONI includes - fiber wires and cables, standard cables, special cables (hybrid), assembly, cable systems and designs, application oriented engineering, services, and modernization.

In a global economy, an industry requires new flexible products, whilst infrastructure is challenged by ever more complex applications. Simultaneously, it is a key prerequisite of our time that safety and risk reduction have to be assured everywhere. We are very keen to support, improve and optimize this interaction between social requirements and technological progress with the help of our high-quality cables and wires. As a competent

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The radiation level is very low because it is self-shielded (< 1 micro is severe in all over the public zone) and there is a built-in safety feature to prevent any radiological unsafe/malfunction-situation of the equipment.

Where space is limited, our electron-beam cross-linked insulation and cable solutions offer excellent di-electric properties at reduced diameters. The wires and cables could reduce the overall weight of cables up to 500 kg per vehicle while doubling the service life and increasing safety.

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E-BEAM from the acceleration and conversion of electricity. When a material is irradiated with e-Beam, the material absorbs the energy and alters chemical bonds, which leads to the modification of the material.

Raw Material and Quality Reduced swelling in oily media

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Customer benefit: Expanded range of uses in oily environments and applications. If accidents occur, it is not necessary to replace all cables.

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Resistance to media and solvents

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Customer benefit: Contact with aggressive liquids, painting, detergents and solvents is possible.

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Mutual compatibility: Largely inert behavior towards connector grommets or seals because it is not necessary to add chemically aggressive components to sheath and insulating materials if electron-beam cross-linking is used.

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Environmentally sound: The technique uses fast “electrons” an equal like in a television tube, another place in which high acceleration voltages and electrical deflection coils are put to use. The process is environmentally-sound and can do without the highly reactive chemicals used for chemically crosslinked cables.

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Customer benefit: This is a responsible contribution to reducing problematic chemicals in the process and in waste disposal.

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Material grade are cross linkable with UV resistance, oil resistance, chemical resistance, halogen-free, flame retardant, mud resistance and special compound for survival to high temperature and high voltage.

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It covers polyethylene base, peroxide base polyethylene, polyolefin base, EPDM base, EVA base, Rubber base and other special co polymer. It meets the special application for SOLAR, Railway Rolling stock, high temperature continuous operation equipment, fire resistance with enhanced mechanical and electrical properties for special application

The e-Beam technique also offers environmental and health benefits. The amount of volatiles produced using this technique is reduced significantly than thermally cured processing. In chemical cross-linking process, the cross-linking agents used for thermosetting resins are toxic, carcinogenic and eliminated in the e-beam process.

A e-Beam cured product often have improved mechanical properties, enhanced insulation resistance properties as compared to thermally cured materials and these are retained, improved. E-beam curing is that it can reduce residual internal stresses in the microstructure of a product. E-beam processing is environment-friendly due to the 100% solid system, as e-Beam generates absolutely no emission, no substrate heating. The process necessitates a very less amount of energy consumption and high speed curing substantially increases productivity when compared with conventional heat treatment process.

The e-Beam processing in wires and cables helps in improving thermal, insulation resistance, di-electric property, chemical resistance property, barrier, impact wear and other mechanical properties to meet the demanding applications of the customers in wires and cables. Process of cross-linking in wires and cables presents the advantages of – increased life, higher temperature withstand capability, higher current carrying capacity, improved physical properties with reduced thicknesses in the cables as compared to the conventional cross-linking process.

The process is very high speed and a sure-shot process for curing. Permanent structure after curing will be symmetrical at the entire circumference provides uniform and better permanent enhances property for mechanical and electrical parameter concern to application requirement.

Market Potential and Demand Shift In our understanding, we foresee a huge potential in sections such as – Indian Railways, Metro Railway, Defence, Marine, etc. This further consists of subsections such as - railway coach and locomotive manufacturing unit, maintenance unit, direct and indirect suppliers to the railway unit; and direct and indirect suppliers to metro railway, etc. At present, the market size of the EBXL cables would be approx. 150 Mio € and is growing at 10-12% CAGR per annum.

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rocess of cross-linking in wires and cables presents the advantages of – increased life, higher temperature withstand capability, higher current carrying capacity,… as compared to the conventional cross-linking process.

Advantages Over Conventional Curing Process E-Beam is an energy which is composed of a narrow stream of electrons in wave form. This energy is created

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Jan-Feb, 2021

E-BEAM

Vindhya Telelinks: Fully Geared Up to Meet Diverse Market Needs

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n view of the increasing demand of E-beam cables in India, we have diversified into the manufacturing of electron beam cross-linked cables by establishing a state-of-the-art manufacturing facility with the latest technology.

Excerpts of the interview with Mr. Ramesh Singh, President (Works), Vindhya Telelinks Ltd: Product Portfolio and Technical Capabilities Cross-linking is the interconnection of adjacent long molecules with networks of bonds induced by chemical treatment or electron-beam treatment. Electron-beam processing of thermoplastic material results in an array of enhancements, such as an increase in tensile strength and resistance to abrasions, stress cracking and solvents.

E-beam technology, that is an ionizing energy, as provided by an accelerated electron beam (EB), is an efficient means of cross-linking polymers used for wire and cable insulation and jacketing. In this process, the three-dimensional un-meltable network is created. This can be done without heat. E-beam processing is fast, good, controllable and in a lot of cases more economical than thermal and/or chemical cross-linking. The electron beam processing in wires and cables helps to improve thermal, chemical, barrier, impact wear and other mechanical properties. The electron beam cross-linked cable offers increased life, higher temperature withstand capability, higher current carrying capacity, improved physical properties with reduced thicknesses.

Our product range of E-beam cables are - locomotive cables for railways, solar PV cables, automotive wires and cables, cables for shipbuilding, windmill cables and EBXL flexible wires.

Mr. Ramesh Singh

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E-BEAM Manufacturing and Technical Setup Vindhya Telelinks Ltd. (VTL) belongs to the prestigious MP Birla group which is a century old group enjoying excellent market reputation due to its superior product quality and support to its customers. The group has been pioneering in the field of power and telecommunication cable industry. Under the umbrella of M.P. Birla group, VTL has earned an enviable reputation and leadership position in the market and has a satisfied customer base in the domestic as well as overseas market.

In view of the increasing demand of E-beam cables in India, we have diversified into the manufacturing of electron beam cross-linked cables by establishing a state-of-the-art manufacturing facility with the latest technology. This E-beam facility has a 3.0 MeV/100KW electron beam accelerator along with suitably designed handling systems for irradiation of 0.5 sq mm to 500 sq mm and cable diameter up to 60 mm. Also, the irradiation of various types of electrical and automotive cables and wires, PE sheets, polymeric tubes/pipes, heat shrink products, gems and diamonds, medical product sterilization. The E-beam irradiation curing of elastomer and other polymeric cables has several advantages over conventional steam/dry curing methods. The Company possesses various system certifications including ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007, TL 9001 & ISO 27001:2013 and is one of the largest and most reputed manufacturers of copper telecom cables, optical fiber cables, railway signaling/quad cables catering to diverse industry segments.

Extrusion Machine

Underbeam handling system for large cable sizes

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Market Footprint Electron Beam cross-linked wire and cables, being superior over conventional cables, are being adopted in all critical application areas such as – railways, defence, solar power, wind energy, nuclear power etc. VTL has emerged as an obvious choice amongst its customers across various sectors and is further strengthening its market position by offering reliable products with the highest quality standards. Our major thrust has been on adopting the most modern and advanced technologies and realizing the benefits derived in creating a strong product line to address the emerging market needs.

TL has emerged as an obvious choice amongst its customers across various sectors and is further strengthening its market position by offering reliable products with the highest quality standards.

wires and cables and sterilization/decontamination of pharmaceutical products.

The materials like PVC/TPU/PVDF/EPDM/EVA/ CPE/PE/ETFE etc. are suitable for E-beam cross linking. The Electron Beam technology can modify the physical, chemical, molecular and biological properties of materials and products, improving their usefulness and enhancing their value. Electron beam accelerator (E-beam Accelerator) is widely used for industrial applications such as – surface curing, cross-linking of

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Raw Material and Quality

Desired properties are obtained by the fine tuning of Electron Beam voltage/current and immediate observation of parameters including – hot set, tensile strength, elongation, etc. The Electron Beam cured product offers distinctive advantages over conventional insulation material.

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E-BEAM T Y P I C A L R E P R E S E N TAT I O N I N TA B L E B E L O W PROPERTY

HFFR 90°C

EBXL - XLPO 125° C

XLPE (Chemical Curing) 90°C

EBXL - XLPE 125° C

Insulation resistance Min. at room temp.

1 x 1010 Ω-Cm

>1 x 1015 Ω-Cm

1 x 1014 Ω-Cm

>1 x 1015 Ω-Cm

At operating temp

1 x 109 Ω-Cm

>1 x 1012 Ω-Cm

1 x 1012 Ω-Cm

>1 x 1012 Ω-Cm

High voltage water immersion test after 6 hrs

6kV

6kV

6kV

6kV

Time Period

5 minutes

5 minutes

5 minutes

5 minutes

Tensile strength Min.

10.0 N/mm2

10-15 N/mm2

12.5 N/mm2

15.0 N/mm2

Elongation at break Min.

>150%

150% - 500%

200%

400%

Cold bend / impact test at

-40°C

-45°C

-15°C

-15°C

Wind ability / bending radius

9 x cable OD

4 x cable OD

12 x cable OD

12 x cable OD

Heat ageing at

80°C for 7 days

Variation in Tensile strength & elongation at break after ageing.

±20%

±15%

±25%

±15%

Hot deformation Max

50%

<25%

50%

<25%

Operating temp.

-40°C to 90°C

-45°C to 125°C

90°C

-15°C to 125°C

Short circuit temp.

160°C

280°C & 300°

250°C

280°C & 300°C

Soldering iron resistance

Insulation melts

Resistant

Melts Reasonably

Resistant

Fire Properties

20%

<10%

NA

<10%

Toxicity Index

<5

<4

>10

<4

Acid gas Max. Emission

Nil

Nil

NA

Nil

Flammability

Melt and Drip

Do not melt or drip

Melt and Drip

Do not melt or drip

Flame propagation

Moderate

Very low

High

High

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150°C for10 days 135°C for 7 days

150°C for 7 days

Jan-Feb, 2021

E-BEAM linking. The curing time is less as compared to chemical curing and the 125°C temperature rating implies – long life, higher ampacity, protection from thermal overloads.

Market Potential and Demand Shift By virtue of its offerings, the E-beam cables are being favored in sectors such as - solar, railways and shipping, where cables are required with cross-linked polymeric insulation with lower insulation thickness for high temperature applications.

Improved abrasion-resistance results in reduced wall thicknesses to save raw materials, space, energy and weight. Also, lower weight gives an extra premium in terms of lower energy consumption in trains, ships, planes and other transportation systems. As a matter of fact, there is no dripping in case of fire, less flame spreading, less smoke, and less pollution in case of fire.

Moreover, no immediate melting means no immediate short circuits in areas like elevators, large public buildings like schools, theaters, airports, stadiums, ferries and so on. There is a reduced risk of damage by mechanical pressure and cut through, no short circuits and electrical sparking and also, improved oil and fluid resistance makes the cables function longer during immersion.

The market for these cables is gradually increasing as new sectors are opening up for this technically advanced product. However, the larger consumer markets are yet to open up for E-beam cables, but due to its superior properties E-beam cables will soon start penetrating these markets in a big way. VTL is fully geared up to deliver cables as per market needs.

Advantages Over Conventional Curing Process

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Some of the major advantages of E-beam over chemical cured cable are - higher degree of cross-linking up to 75-80% in E -beam cables as compared to the 50-55% in chemically cross-linked and there is no polymer degradation due to the exposure to high temperature as EB cross-linking occurs at room temperature. In addition, there is no oxidative degradation in polymer due to leftover chemicals, oxygen in air and operating temperature of cable, as observed in chemical cross-

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he market for these cables is gradually increasing as new sectors are opening up for this technically advanced product.

Jan-Feb, 2021

E-BEAM

APAR Industries: Foreseeing a Promising Potential and Future for the E-Beam Wires and Cables

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n my opinion, the entire PVC wire and cable market will switch to EBXL wires and cables as the awareness for EBXL is projected to increase substantially.

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Excerpts of the interview with Mr. Ajeet Singh, General Manager – Sales & Marketing, APAR Industries Limited: Brief Overview of the Company

Established in 1958, APAR Industries Limited, having revenue of Rs 7500 Cr, provides solutions to its customers in more than 125 countries in the business segments of – specialty oils and lubricants, overhead transmission conventional and high-temp conductors, copper catenary wires, OPGW, electrical and telecommunication cables in India.

We, at APAR, are poised to embark on our mission “To design and manufacture building blocks for energy infrastructure, transportation and telecommunication sectors that contribute meaningfully to a safer place”. We have always believed to be in the leadership position in all the product segments. In 2008, Apar took over Uniflex Cables Ltd. and merged it with APAR Industries Ltd. with effect from 1st April 2010. We have grown year after year from about INR 100 crore to over INR 1600 crore in the period of ten-eleven years, registering a growth rate of > 25 % CAGR. Now, we are well positioned among the top five- six power cable manufacturers in India and are known for the high quality of all our products.

By leading the innovation curve, we deliver to our global customers - “Tomorrow’s Solutions Today”. The word ‘innovation’ is an integral part of our DNA and the concept is widely spread among our team members, and is not limited to a few. The innovation is not only for the end products, but also in our processes across various functions.

Mr. Ajeet Singh

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The cable division of APAR is a pioneer in the manufacturing of various kinds of cables. We cater to sectors including – power generation, transmission & distribution as well as specialized sectors such as marine and shipyard, oil & gas, railways including loco/coach wiring and metro railway, mining, renewable energy, etc.

We are an ISO & OHSAS-accredited manufacturer and we also hold the UL-certification for certain sections of cables. Moreover, our testing Lab is accredited by NABL as per ISO: 17025.

e have set up a state-of-the-art 1.5 MeV, 2.5 MeV and 3.0 MeV Electron Beam Accelerators, along with suitable handling systems that have been installed in our facility in western India, which is based at Khatalwada in South Gujarat.

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Our range of wire and cable products include: LV/MV/ HV, XLPE power cables up to 66 kV, building wires/ house wires/flexible/FRLS/FS/control/instrumentation cables, medium voltage covered conductors (MVCC); and elastomeric (rubber) cables up to 33 kV. In addition, we also provide – optical fiber cables (including fireresistant/survival type), windmill and solar DC cables as per EN/TUV standards (renewable sector), specialty composite/hybrid cables, electron-beam irradiated cables; and 105°C XLPE cables.

Gujarat. Our two E-BEAM equipment were installed in 2011 and we have almost a decade long experience in the manufacturing of the e-beam wires and cables.

We have a fully trained in-house team to handle the machinery, and to manufacture world-class products.

Also, AERB (Atomic Energy Regulatory Board) has been supervising the installation periodically.

Product Portfolio and Technical Capabilities

Market Footprint

APAR has developed specialty EBXL (Electron Beam Cross Linked) cables that are in-house manufactured.

Company’s Anushakti wires come with PVC of 105˚C rating that enhances physical and electrical properties of the insulation material. This improves the insulation resistance, reduces leakage current, makes the wires non-melting, improves the current carrying capacity by over 50%, thereby, it provides protection against electric shock/short-circuit, for fire safety. The wires are far superior to any conventional FR PVC wires available in the market that do not catch fire.

At present, we are operational in the southern and western India market. However, we are also intermittently serving the markets in Delhi-NCR, and Kolkata. We are open to serve anywhere in India for bulk orders.

We are exporting huge quantities of EBXL solar cables in the international market, besides being a leading player for EBXL supplies to railway coaches, locomotives and ship building applications.

APAR Anushakti wires can be widely used wherever fire safety, short circuit and overloads are some of the major concerns. As a matter of fact, it must be used in all residential and commercial applications, especially in highly crowded area viz. hotels, hospitals, schools and colleges, airports, malls, and multiplexes and high rise buildings.

Abreast of the technologies worldwide, APAR “Anushakti wires” are manufactured with E-BEAM technology and exhibit extended properties such as – high-temperature withstanding capacity up to 105˚C, high-current carrying capacity, and prevents shortcircuits. They are heat and melt-resistant and thereby, are solder iron-resistant. Moreover, the wires qualify the Hot Deformation Test, they are able to reduce smokes, and have a longer operating life span.

We are planning to explore the market through - retail, project, OEM industry, and the government through — our channel and directly. To create awareness about EBXL products, we are exploring digital and BTL routes.

We have our team in the field who are consistently working to create awareness among the influencer mainly electricians, builders, consultants, and the government and semi-government departments.

In addition to the aforesaid properties, the wire and cable products are also environment-friendly, safe, and ideal for the high-end and safety projects. The area range of APAR Anushakti wires are: single core from 0.75 sq. mm to 240 sq. mm conductor area.

Raw Material and Quality

Manufacturing and Technical Setup

The various materials used for EBXL are PVE and Polyolefins. All of these require specialty formulations, which is done in-house in our compounding facility. This gives us a sense of control on the quality, and also, it keeps the costs under control. The extrusion equipment

We have set up a state-of-the-art 1.5 MeV, 2.5 MeV and 3.0 MeV Electron Beam Accelerators, along with suitable handling systems that have been installed in our facility in western India, which is based at Khatalwada in South

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E-BEAM

are also specially customized to meet the various requirements pertinent to these wires and cables. Ably supported by a competent engineering team, and quality control systems, we are able to offer the highest quality.

APAR has been working diligently to create awareness among all the stakeholders; mainly through BTL and Digital routes; we are closely working with all the influencers and installers. They are mainly electricians, retailers, dealer, consultant, contractor, interior designerarchitect, industries and Govt. departments. We are frequently organizing meets and webinar too. To create mass awareness, we do participate in exhibitions such as – Elecrama, Ace-tech and others.

Market Potential and Demand Shift In my opinion, the entire PVC wire and cable market will switch to EBXL wires and cables as the awareness for EBXL is projected to increase. Some more players have already ventured in the segment and this will enhance the awareness about the EBXL wires and cables. Some of our competitors are also intending to install the e-beam facility and some of them have already installed it.

However, at present, they are not using it for wires. The customer shift to e beam wire cable is a bit slow in pace, because of the lack of awareness among end-consumers and influencers.

Now, we have also taken the digital route to promote the EBXL products, especially, on the social media platforms i.e. LinkedIn, YouTube, Twitter, and Facebook, where our brand is showing footprints, and is gaining good reach. Similarly, we are also planning to venture into the e-commerce space.

We are quite confident and assured that the EBXL segment has a great future in the domestic market, developing countries as well as developed countries.

This is the need of the hour, and it must be installed in all the electrical installation systems, be it residential or commercial, private or public. To make the premise firesafe, APAR Anushakti wires and Mahashakti cables are highly recommended.

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PAR has been working diligently to create awareness among all the stakeholders; mainly through BTL and Digital routes; we are closely working with all the influencers and installers.

They are mainly electricians, retailers, dealer, consultant, contractor, interior designer-architect, industries and Govt. departments.

Advantages Over Conventional Curing Process The conventional method of cross-linking is based on thermally induced “chemical cross- linking”, which has drawbacks including – it is carried out at high temperature which affects the life of polymers due to degradation caused by high temperature exposure.

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On the other hand, the electron beam cross- linking is carried out at room temperature and with the electron– beam accelerators; the insulation materials can be cross–linked within a few seconds. The homogeneous irradiation ensures that the homogeneous cross-linking is achieved. The term ‘irradiation’ simply implies the act of applying radiation (for radiant energy) to some materials.

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E-BEAM

Polycab: Shift towards the New Generation E-Beam Cross-Linked Cables is the Natural Next Step

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t Polycab, we are completely equipped for cross-linking insulation and sheathing compounds… We are fully geared up to meet the increasing demand for EBXL cables in the domestic as well as international market.

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Excerpts of the interview with Mr. K R Chandrasekar, Executive V.P., Polycab India Limited: Product Portfolio and Technical Capabilities

Our product range for the Electron Beam Cross-Linked (EBXL) wire and cable segment are as follows: cables for applications such as - rolling stock (railways and metro rail), automotive, defence, solar power installations, and process industries.

The Electron Beam Cross-Linked Cables are technically superior as compared to other cables and are predominantly used in applications that are very critical for the safety of human life. These cables are capable of operating in extreme environmental conditions. The design life expectancy of EBXL cables is generally in the order of twenty-five years.

Some of the standout features of the EBXL cables include: they are thin-walled, lightweight, have a reduced diameter, and a high current carrying capacity. Also, they exhibit resistance to – UV, water, ozone, mineral oil, detergents, fluid, oil, salt, and solvents. Further, they are halogen-free, flame-retardant, and resistant to high temperature.

Mr. K R Chandrasekar

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E-BEAM

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The properties of EBXL cables also include resistance to - high abrasion and dynamic cut-through (further testified through the dynamic cut-through test) and they are also highly flexible and easily strippable.

he demand for e-beam wires and cables is projected to increase in the coming years, because of its superior thermal, electrical, mechanical and fire properties.

At Polycab, we have adequate capacity for cross-linking insulation and sheathing compounds by electron beam irradiation process. We are fully geared up to meet the increasing demand for EBXL cables in the domestic as well as international market.

In addition, we also use insulation and sheathing compounds which are developed in-house at our R&D centre which clearly demonstrates our end-to-end capabilities.

Market Potential and Demand Shift The demand for e-beam wires and cables is projected to increase in the coming years, because of its superior thermal, electrical, mechanical and fire properties. Any installation which is prone to fire hazards and safety of human life will shift towards e-beam cables in the near future.

Market Footprint At present, we have presence in the following market segments – rolling stock application in railways and metro rail, automotive industry, defence, electric vehicles, and solar power installations.

As a market and technology leader, we have already invested in increasing our capabilities to fulfill the increasing demand.

We plan to increase our reach by offering the best quality products manufactured in our state-of-the-art manufacturing facility.

Advantages Over Conventional Curing Process

Raw Material and Quality

The e-Beam curing process has a number of advantages over other conventional curing processes including the fact that it is an eco-friendly and green process causing zero environmental pollution. Moreover, it also ensures extended functional life and since it doesn’t include the use of any unwanted additives, it doesn’t yield any byproduct assuring better electrical properties to the main product.

Polyolefin copolymers are used as insulation and sheathing compound. These compounds have a number of properties which give them a competitive edge in the market, that is, they have zero halogen content, flameretardant characteristics, and have elastomeric properties which imply they are highly flexible. Moreover, since they are cross-linkable, it further enhances the thermal, electrical and mechanical properties of EBXL wires and cables.

Additionally, the fact that it operates at room temperature ensures material stability and further, it also results in improved mechanical, electrical, and chemical properties at elevated temperature. As a matter of fact, the e-Beam curing process is precise, regulated and controlled, resulting in minimum wastage.

As mentioned earlier, we develop all the above compounds in-house which ensure the consistency and reliability in our product range.

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Manufacturing and Technical Setup

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E-BEAM

Thermo Cables Limited – Demand and Application of E-beam Wires and Cables are Projected to Rise

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aving established ourselves as a prominent player for EBXL cables in the domestic market, we are now looking for more opportunities in the global market with renowned transport companies…

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Excerpts of the interview with Mr. N Srinivasa Rao, President, Thermo Cables Limited: Product Portfolio and Technical Capabilities

Thermo Cables Limited is a specialty cable manufacturing company that is synonymous with quality and satisfying customers’ needs in the most critical areas. Our product range includes – LV power & control, instrumentation, thermocouple, fire resistant, high temperature (PTFE, FEP, PFA, ETFE, ECTFE and SiR), E-beam, elastomeric and other specialty cables.

With the addition of the E-beam facility, our supplies are extended to railways, navy - ships & submarines, offshore, marine, wind mills, solar plants and material handling sectors. The E-beam wire and cables offer superior performance in demanding applications, and in extreme environments.

Manufacturing and Technical Setup Presently, we have a 3-MeV accelerator and another 2-MeV accelerator is under installation. Our 3-MeV accelerator is equipped with a reflection magnet which collects unused energy and reflects back onto the cable which increases the depth of beam penetration and enables to cross-link cables of large diameters.

Mr. N Srinivasa Rao

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Market Footprint We have made good progress in terms of approvals with Indian railways and Indian navy who are the major consumers of the E-beam cables. We have become an approved supplier after satisfying qualifying requirements with Indian railways in a short period of time as compared to our close competitors. There’s been a surge in our international marine sector business for EBXL cables after obtaining ABS approval and we’ve also got ourselves associated with global wind companies.

ith an estimated potential of Rs. 2,000 cr per year in the domestic market for E-beam wires and cables, we would like to have as much share as possible from this consistently rising demand.

Market Potential and Demand Shift

With an estimated potential of Rs. 2,000 cr per year in the domestic market for E-beam wires and cables, we would like to have as much share as possible from this consistently rising demand. We are educating our customers about the advantages of the E-beam cables over conventional cables and going forward, we are confident of the customers demanding E-beam cables for many of their applications.

Raw Material and Quality Using the right compound is essential for E-beam cables and we are proud to have our own compounding facility which ensures quality, shorter lead times and competitive prices. We are making various compounds such as EPDM/EPR, EVA, CPE, PCP, CSP, SHF2, and LHLS for non-toxic and non-corrosive halogen-free E-beam cables that are used for critical applications in railways, navy, windmills, solar plants etc. While processing these compounds, we consider features such as - tensile strength, elongation, hot set and permanent set, fire properties, halogen content, toxic levels etc., which are very important for the performance of E-beam cables.

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Advantages Over Conventional Curing Process The benefits and advantages of E-beam cross-linking are well-established and it is the most important commercial application of radiation technology. The major advantage of the E-beam cables is that they are lightweight with reduced diameters due to thin wall insulation/jacketing with improved service life than the conventional curing process. The E-beam cables are cured at room temperature whereas conventional curing is done at higher temperatures and may deteriorate the thermal properties of the insulation/jacket materials.

Some of the other advantages include – improved service/operating temperature, increase in current carrying capacity, and improved mechanical properties.

Moreover, the service-life of the cable is also increased with this process, which is environment-friendly and ensures uniform curing of the cable. Also, the E-beam cables have improved abrasion-resistance; high throughput, improved flame propagation resistance, and reduction of short-circuit conditions.

sing the right compound is essential for E-beam cables and we are proud to have our own compounding facility which ensures quality, shorter lead times and competitive prices.

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At present, we are serving to – railways, shipbuilding, marine, offshore, wind mills, solar plants and material handling industries. Having established ourselves as a prominent player for EBXL cables in the domestic market, we are now looking for more opportunities in the global market with renowned transport companies such as - Siemens, Alstom, Bombardier Inc., etc.

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E-BEAM

Anand International: E-Beam Cross-Linked Cables to Get Accentuated Reach and Usage in Near Future

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e see an enormous future for e-beam cables and it is only a matter of time that you’ll see these types of cables being used in almost all the applications.

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Excerpts of the interview with Mr. Manish P Jiwani, Chairman, Anand International: Product Portfolio and Technical Capabilities

At present, we’re an emerging company in the wire and cable industry. Our main focus is on EBXL wires and cables, which includes – solar cables, high-temperature wires, EBXL PVC cables, and many more.

The Electron Beam Cross-Linked (EBXL) solar cables offer superior performance in extreme environments.

The cable can continuously operate at 125 degree C temperature. It has better UV and ozone resistance and exhibits improved weather resistance in adverse conditions. Also, the cables have an improved oil, chemical, and crack resistance and also possess improved mechanical properties at elevated temperature conditions.

Manufacturing and Technical Setup We have a state-of-the-art in-house unit for manufacturing e-beam wires and cables followed up by a testing facility of the complete range of cables. Moreover, we’re still the first and the only company in India that is involved in providing beaming services in the cable industry. We believe that we’ve given small and medium cable manufacturers a push to get into the e-beam wires and cables sector.

Mr. Manish P Jiwani

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E-BEAM Market Footprint It has only been a few years since we’ve started manufacturing EBXL wires and cables and so far, we’ve received a positive response from the market. At present, we’re planning to cater our products to the international market as well in the next financial year. In addition, we also intend to establish our presence in the railway cable segment for Indian Railway.

Raw Material and Quality

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Earlier, the e-Beam compounds were quite challenging as it had to be compatible with irradiation doses. However, nowadays, a few companies have developed indigenous e-beam compounds which are easily available in the market at competitive prices. These companies have a proven track record of the compounds they supply which maintain good quality.

his is a Green Technology which helps to enhance product life and performance in adverse conditions, is very efficient, and enables us higher throughputs.

We see an enormous future for e-beam cables and it is only a matter of time that you’ll see these types of cables being used in almost all the applications. We have actually started our beaming division as a service provider and we’ve touched almost every cable company to start manufacturing e-beam cables. In fact, five years ago, there were only a handful of pertinent machinery in India, and then we came up with an idea where other cable manufacturers could bring their cable at our premises and we undertake the curing process for them.

The trend so far has been good and we’ve been receiving a positive response from the industry.

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Market Potential and Demand Shift

Technology which helps to enhance product life and performance in adverse conditions, is very efficient, and enables us higher throughputs.

Advantages Over Conventional Curing Process Talking about the advantages, the technology is well accepted throughout the globe as the process is easily controllable with very tighter tolerances. It gives higher productivity which enables one to reduce the operating costs and also increases the life of a cable. Since the process does not require any additives, it doesn’t generate any hazardous chemical by-products. This is a Green

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t present, we’re planning to cater our products to the international market as well in the next financial year. In addition, we also intend to establish our presence in the railway cable segment for Indian Railway.

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COPPER FOCUS

Leebo Metals:

Aspiring to Expand Capacity & Market Footprint “While maintaining an exorbitant pace of growth, one of the main goals for the next two years is to install and achieve a target of about 40000 MTPA by 2023. In addition, we plan to increase the customer base to reach more than 1000 active customers, and aspire to be the undisputed leader in quality metal supply” - Mr. Rajesh Agarwal Rajesh Agarwal: Incorporated in 1995, Leebo Metals has been manufacturing and exporting high-quality copper products to its customers across the globe. The Group consists of two companies, namely — Leebo Metals Private Limited and Omega Rolling Mills Private Limited. These companies are involved in the manufacturing of copper and copper-based products.

As a globally-responsible corporate entity, Leebo Group continues to originate systems and services to create products that are backed by significant innovations that support a sustainable future. Leebo Group is committed to improve operational efficiencies through customercentric inventions to ensure the safe applications of the products.

From its fully equipped manufacturing plant in Daman with an annual capacity of 15000 MT, Leebo Metals has a PAN-Asia distribution network — facilitating timely delivery of the products to the clients. Right from the choice of the raw materials, designing the work environment to meet six sigma metrics, to the installation of modern-day & cutting-edge machinery, and a tool room, the company is thoroughly committed to the cause of zero-waste, and to be sustainable in its entire production operations.

Mr. Rajesh Agarwal

The other plant — Omega Rolling Mills Pvt. Ltd. is situated at Boisar- District Palghar in Maharashtra, and

Mr. Rajesh Agarwal, Managing Director, Leebo Metals Private Limited, outlines the business story of the Company, the two subdivisions of Leebo Group - Leebo Metals Private Limited and Omega Rolling Mills Private Limited, manufacturing capabilities, product range, and Group’s future plans in an exclusive interview with Wire & Cable India.

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The Group consists of two companies, namely — Leebo Metals Private Limited and Omega Rolling Mills Private Limited.

Wire & Cable India: Tell us about Leebo Group? Shed some light on the manufacturing set up of the company describing the core capabilities and the infrastructure?

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COPPER FOCUS

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While maintaining an exorbitant pace of growth, one of the main goals for the next two years is to install and achieve a target of about 40000 MTPA by 2023. In addition, we plan to increase the customer base to reach more than 1000 active customers, and aspire to be the undisputed leader in quality metal supply.

From its fully equipped manufacturing plant in Daman with an annual capacity of 15000 MT, Leebo Metals has a PAN-Asia distribution network — facilitating timely delivery of the products to the clients.

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WCI: What are the different industries you serve with your product range?

is just 120 Kms from Mumbai. It is a fully equipped plant admeasuring about 6000 sq.m, with a 6000 MT annual capacity. The plant is equipped with a complete range of sophisticated machinery to undertake end-toend production from melting, Konform extrusion, cold rolling and drawing, all done under one roof. Further, an in-house machine shop has all the necessary machinery which is extensively used in the research & development activities and also in carrying out production operations of the plant in a seamless way.

RA: Leebo Group is one of the leading manufacturers of copper components in India. Our products find applications in a number of industries — namely, electrical panel board industry, thermal power industry, switchgear industry, wind power industry, bushing manufacturing industry, transformer manufacturing industry, to cite a few.

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WCI: A brief on the product portfolio of Leebo Group and the various markets you serve? What are the plans for the future?

The other plant — Omega Rolling Mills Pvt. Ltd. is situated at Boisar- District Palghar in Maharashtra, and is just 120 Kms from Mumbai. It is a fully equipped plant admeasuring about 6000 sq.m, with a 6000 MT annual capacity.

RA: Leebo Group engineers all kinds of industrial applications of copper with the help of its sophisticated machinery and skilled manpower. Our product range includes Cu upcast rods, Cu flats & strips, Cu foils & sheets, Cu wire rod & wires, Cu customized products – sections & profiles, outsource Cu tubes & pipes and Cu conductors & PICC.

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WCI: Considering the crisis ensued due to the pandemic, what were the different strategies which have enabled you to face the challenges?

RA: You cannot control the world, but you can control how prepared you are to deal with it, and nothing prepares you better for dealing with the unprecedented challenges than being well-rested. Aware of the challenges ahead, we have restructured our investments, sales and trading businesses, and accelerated our efforts to cut the costs.

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NEW DEVELOPMENT

Maillefer Extrusion: Prioritizing Local Manufacturing in India Maillefer has strengthened its support and presence in India by introducing local manufacturing and supply of brand name technology destined to low voltage wire and cable manufacturers within the country. highly valued. Our new approach will provide the availability of high-quality Maillefer technology directly in India.

WCI: How do you view the company’s prospects in the Indian market and what will be your strategies for serving the needs of the market and building a robust local supply chain?

Mr. Lars Fagerholm, CEO

In an exclusive joint interview with Wire & Cable India, Mr. Lars Fagerholm, CEO and Mr. Mikko Lahti, R&D Director, Maillefer Extrusion Oy, shed light upon the announcement of the local manufacturing in India, the key strengths of the product range, the recent innovations, details about the product development process, and their outlook on the crucial importance of automation and AI in improving efficiency, and optimizing operations.

Wire & Cable India: Maillefer has recently announced its expansion in India by introducing local manufacturing and supply of brand name technology; could you please elaborate on this development?

Lars Fagerholm: The low voltage machinery in the Indian market is today quite diversified when it comes to the demand of technology. The recently announced local Maillefer manufacturing is focusing on the specific needs to expand the offering available. We also believe that the local manufacturing and support to our customers in India will be

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LF: The low voltage cable market will strongly boost in India driven by urbanization and its consumption is projected to have mid and longterm growth. The population in urban regions is annually growing by more than 2.5%. This strong trend combined with the green energy initiatives is making India one of the potentially fastest-growing cable markets. Maillefer has a long history in India and we have a local sales and service team in Mumbai. It is our strong intent to follow this potential market growth, and assist with the best suitable portfolio and support.

This is where the local supply chain will play an important role.

WCI: Could you please briefly touch upon the product portfolio of Maillefer India for the wire and cable sector? Also, delineate on the key strengths of the product range.

Mikko Lahti: Maillefer covers the whole extrusion related wire and cable portfolio in India. We offer different lines from power cable manufacturing to copper telecom production. In power cable manufacturing, our strength is based on a very deep process knowledge which gives us competitiveness against our competitors. The process know-how is also the base for all innovations which keep us as a forerunner in this industry. The latest example of this is our patented round curing concept in power cable manufacturing that

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combines productivity with excellent product quality. In fiber optic cable production, our strength is in the world’s fastest secondary coating line.

We have recently introduced the first autonomous secondary coating line to the market wherein we have combined the end product quality with the process model and the line is capable of controlling itself according to the end product quality. Maillefer has a wide range of offerings in the low voltage segment. In that segment, our key technology is extrusion. Our extruders offer a stable and constant output that our customers can reduce the overconsumption to the minimum and make remarkable material savings. In telecom applications, the physical foaming combined with our extrusion knowledge is the key to success.

WCI: Has there been any development or innovation with respect to the product offerings and any technological upgradation in the recent past?

ML: In power cable manufacturing, we have introduced several

Mr. Mikko Lahti, R&D Director

Jan-Feb, 2021

NEW DEVELOPMENT

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“We have recently introduced the first autonomous secondary coating line to the market wherein we have combined the end product quality with the process model and the line is capable of controlling itself according to the end product quality.”

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innovations during the recent years.

In catenary lines, we have attached the post heater in the neutral zone.

Then customers could achieve higher line speeds without having the risk that the drooping will ruin the cable geometry. The recently patented solution is our round concept where rapid impulse heating is introduced to the insulation material directly after the crosshead in the curing tube. This enables extreme productivity with excellent product quality. We have also developed a new measurement device called topography scanner, which offers a way to continuously monitor extrusion quality, find an optimal set of parameters, and increase CV line productivity. Another notable aspect of this device is the ability to scan the whole cable core surface during production. If there are any defects visible on the cable core surface, they are detected and immediately reported to the operator.

WCI: With a vast portfolio of more than 50 technologies, Maillefer also holds 22 patent families, which is the highest in the industry. Could you please take us through the product development process in the wire & cable segment succinctly while also describing the key value proposition which makes the company one of the leading players in the sector?

ML: Maillefer has a wide customer interface. We annually collect the customer needs through our sales and agent network as well as our own technology group. Then all the inputs are listed and prioritized. Every year, we run around 3-6 different R&D products covering some of our applications. We need to minimize the number of projects in order to increase the efficiency of finalizing

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them. On top of that, we do several small product maintenance projects to keep our portfolio operational.

Considering our long history of developing technology for the wire and cable industry, I would say that we have gained an immense knowledge of the processes. The data collection, its analysis, and implementation are what that helps us constantly improve our lines and get an edge over the competitors.

WCI: Kindly give a brief outline on the Company’s efforts in R&D and innovation. How pertinent do you consider the role of innovation to ensure productivity and attain consistent growth?

ML: The equipment’s efficiency is the most crucial factor as far as manufacturing activity is concerned.

There are times when our customers are interested more in knowing the outcome of a solution that we provide than in the initial investment. We basically want our solution to prove cheaper for the customers in the long run and it has turned out to be true with our existing customers, who are getting a definite payback. Despite the positive implications of our solutions, in the long run, pricing often comes as a difficult topic to discuss with Indian clients. We are always more than ready to prove how our solutions would prove cost-effective with quality yield over a long period.

WCI: Since the application of AI and automation technology enables the manufacturer to improve efficiency, fasten processes, and optimize operations; how would you describe the factors and technological capabilities which give a major competitive advantage to Maillefer in this regard?

ML: At present, the trends such as AI and automation are causing a great upswell of interest in industries across the spectrum and are a big driving force for us as well. Today, data is a greatly powerful tool – to closely monitor and control operations. In our AI solution, everything is based on a huge amount of data and the deep knowledge from the processes under investigation. However, mere

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data collection is of no use unless it is analyzed to troubleshoot and upgrade the technology. Even though the industry has the data for decades, its convincing use has still not begun.

We are measuring a huge pile of data in the product lines that we are offering. Presently, we have also started to utilize the data. Nowadays, we have our first real AI offerings launched to the market - smart buffering and topography scanner.

In smart buffering, the line can autonomously control itself leading to extremely efficient production with minimal raw material consumption.

In the topography scanner, we have developed a neural network-based inspection method for identifying defects from the cable surface which will help our customers to save remarkable amounts of money, not making scrap in the post processes.

We know what data should be measured and what devices should be used in our lines and machines.

The devices help us to analyze the data and make decisions in terms of controlling our actions. This utilization of data immensely helps us in our R&D with regard to designing a perfect machine. Designing and manufacturing machines are basically what we do, but once we have analyzed previous data we can envision better machines – more efficient extruders and crossheads. A deeper knowledge of the process is also critical in order to better utilize the data to get a conclusive idea of how the machines have been working previously and how we can optimize it more. Hence, the acute data measurement and analysis coupled with extensive process knowledge is the key to the success of our R&D.

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“We have also developed a new measurement device called topography scanner, which offers a way to continuously monitor extrusion quality, find an optimal set of parameters, and increase CV line productivity.”

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Jan-Feb, 2021

NEW BRANDING

Kemtree:

Striding Ahead With Renewed Vigour and Vision “As we move forward, we understand that branding plays an especially important role in today’s business world and we believe that KEMTREE will certainly become a strong brand in the coming times.” company in 1995-96 known as Ronak Industry, where we began working with Traxit International GmbH (known as August Neuhoff at that time). Slowly over a period of time, we collaborated with several companies from Europe and the USA to get the best products available globally for the Indian wire industry. As more hands from the family joined the business, we had the confidence and aspiration to do something bigger for the Indian Steel Industry. This is how we started KEMTREE – where we manufacture industrial lubricants for a range of applications. Even with our manufactured products, we try to offer speciality solutions to our existing customers as well as new ones.

As we move forward, we understand that branding plays an especially important role in today’s business world and we believe that KEMTREE will certainly become a strong brand in the coming times. And as we celebrate the 25th year of our service to the steel industry and the wire industry specifically, we believe this is the right time to re-brand all our businesses as KEMTREE.

WCI: As you represent some of the world class technology solutions providers, please give us a glimpse of your product offering for various applications. Is there any plan to diversify your current portfolio in the future?

Mr. R. P. Shah

RPS: Our focus is to work with companies whose vision aligns with ours. Every company that we work with is a specialist in their areas and has products and services of the highest quality. We offer wire drawing lubricants, pressure die systems, wire drawing machines, wire plating and cleaning lines, spares for the wire drawing machines, wire straightening units, lubricant applicators, descaling brushes and many other products that are used particularly for steel and stainless steel wire production.

In addition, we provide wire rope lubricants which can be used for the primary as well as secondary applications.

Also, we have started manufacturing a range of cleaners for stainless wires and tubes, some single pass drawing

Wire & Cable India interviewed Mr. R. P. Shah, Managing Director, Kemtree Enterprises Pvt. Ltd., wherein he presents us a rundown on the recent rebranding of the business as Kemtree, their product portfolio, the market reach of the Company, the approach towards sustaining efficiency, and their future plans going ahead.

Wire & Cable India: Could you please tell us about the recent rebranding of the company? Also, please chart out some significant accomplishments of the company in its 25 years of the business journey.

R P Shah: At the outset, I had started a trading

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NEW BRANDING oils for thick sizes and general lubricating oils and grease for the steel industry.

We sell high-quality cold rolling mills for making shaped wires and strips. The response for the same has been phenomenal and the demand for such lines is growing every year. Now, our focus is positioned on the steel (hot) rolling segment where we are in early talks with some eminent companies from Europe who can undertake complete turnkey projects.

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Now, our focus is positioned on the steel (hot) rolling segment where we are in early talks with some eminent companies from Europe who can undertake complete turnkey projects.

WCI: What is the long-term corporate vision?

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L to R: Mr. Karan Shah, Director Mr R P Shah, Managing Director, Mr. Ronak Shah, Director

recently started manufacturing in India. Right now, we are taking it one step at a time. We have always focused on our existing customers and always try to offer them more products and services. Our next step will be to explore customers within India as well as in other countries with products which are manufactured in India.

RPS: Our long-term vision is to be a complete solutions’ provider to the steel industry in India and across the globe. Again, this will be achieved only by providing products and services that are of the highest quality at a reasonable pricing. It will be our constant endeavour to establish KEMTREE as a brand that can achieve this vision.

WCI: What kind of steps does your company undertake to help clients to achieve quality and efficiencies in their operations?

WCI: Kindly shed some light on the market footprint of the company – both domestically and internationally.

Are there any plans to further expand your reach to unexplored markets?

RPS: All our principal companies are experts in their respective field, and they are accessible to all our customers. We strive to educate our customers technically which helps them to make the right decisions. Once the project or a trial is complete, we stay with the customers for all after-sales support.

RPS: In India, our major focus from the beginning has been to serve the high carbon and stainless steel wire markets. We also see that our business is picking up in the low carbon wire segments. With every customer focusing on productivity, it is important that the machines operate at higher speeds and still maintain optimum tool life, better surface finish and physical properties. This is the challenge that we like to undertake and help our customers achieve their goals.

We also try and keep our customers abreast with the latest developments around the globe, which helps them to implement new processes in their production cycles.

WCI: What are your thoughts on the current market scenario and the opportunities ahead?

At present, we’ve been exporting some small quantities and our goal is to also export the products that we have

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RPS: We believe that the good times for business in India have recently begun and will continue for a long time. The government is spending a huge amount on Infrastructure development every year, which will always keep the demand for steel high. We are a nation of more than 1.3 billion people, making our nation a selfconsuming economy. The future for Indian businesses looks very bright and we believe we have a long way to go.

At present, we’ve been exporting some small quantities and our goal is to also export the products that we have recently started manufacturing in India.

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Jan-Feb, 2021

INTERVIEW

Woywod:

Indian Market is Quite Dynamic and Exhibits Huge Potential “The knowledge of the requirements and concerns of the cable industry has helped us to develop special solutions for this industry in particular”- Mr. René Günther Mr. René Günther, Sales Director, Woywod Kunststoffmaschinen GmbH & Co. Vertriebs-KG, takes us through the primary areas of focus for the Company, the manufacturing capabilities, their innovative product offerings, and their perspective on the Indian wire and cable sector in an interview with Wire & Cable India.

Wire & Cable India: To start with, could you please give us an overview of the business journey of Woywod?

René Günther: For more than 40 years, Woywod Kunststoffmaschinen GmbH & Co. Vertriebs-KG has been producing and marketing the PLASTICOLOR range of products, which includes – single dosing units, double dosing systems, volumetric and gravimetric mixing stations, as well as gravimetric throughput measurement systems, hopper loaders and drying equipment.

In the early days, PLASTICOLOR single dosing units and color change systems were produced. The next step was the introduction of volumetric mixing stations and thereafter, followed by the gravimetric mixing stations. In order to complete the range of products, we have added the hopper loaders as well as drying systems (Dry air and desiccant dryers).

Mr. René Günther

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Jan-Feb, 2021

INTERVIEW

Manufacturing Unit at Halol for OFC, FRP/ARP, IGFR and Communication Cables

WCI: Kindly shed some light upon the manufacturing capabilities of the Company? Also, please describe the core capabilities and the infrastructure of your manufacturing facilities.

WCI: Could you please take us through Woywod’s innovative product offerings? Also, outline the key strengths which have played an enormous role in presenting the company with the competitive advantages in the plastic processing and extrusion technology segment?

RG: The production facility in Seefeld (nearby Berlin) has a ground space of approximately 17,000 square meters, with more than 3,200 sq m production area and 800 sq m office for the internal administration and development department. In this location, the above range of PLASTICOLOR products is being manufactured and assembled.

RG: Based on the modular system, a tailor-made system can be assembled for each customer. Manual or pneumatic operated neckpiece slides for a quick and easy color/product change have been developed for the cable extrusion and other related industries. Of course, these can also be integrated into the well-known mixing station concept, which ensures a reproducible production over the entire speed range of the extruders.

The management, general administration and sales department are located in Gräfelfing (in the outskirts of Munich) on 400 sq m office space. Based on the constant development work and efforts, we have been able to attain outstanding high product quality and as a result of this, the precision in dosing and mixing for the end-users has also been increased.

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There are several types of dosing units for various output ranges. These are combined with different neckpieces, weighing hoppers, storage hoppers and individual controls to give the customer a perfect product. The knowledge of the requirements and concerns of the cable industry has helped us to develop special solutions for this industry in particular. One of the key ways to attain growth is and will always be innovative thinking and acting upon that, as well as technical development for practicable solutions.

We have been able to attain outstanding high product quality and as a result of this, the precision in dosing and mixing for the end-users has also been increased.

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WCI: Has there been any recent development or innovation at the Company with respect to the product offerings?

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INTERVIEW

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The Indian market is one of the fastest growing markets that is veering towards high quality products and it is definitely one of the most interesting and dynamic markets today.

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RG: In the past few months, several series of dosing units have been modified to meet today’s safety and hygiene requirements. In view of the stringent considerations and SOP due to the COVID-19 pandemic, brushless motors and matching controls have been introduced, that is one of the innovations introduced in the recent past.

Moreover, there is a self-cleaning dosing station for the industry that has been presented during the last Wire exhibition.

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WCI: Please touch upon the different markets you serve.

How pertinent do you consider the Indian market for the Company in the present time and what is your outlook on the potential of the market?

RG: The PLASTICOLOR product range is being utilized in more or less all areas of plastic processing. As for their applications, the customers are coming from the injection molding market, from the film and flat sheet extrusion, as well as the cable and pipe manufacturing industry.

The PLASTICOLOR product range is being utilized in more or less all areas of plastic processing.

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The Indian market is one of the fastest growing markets that is veering towards high quality products and is definitely one of the most interesting and dynamic markets today. We foresee a huge potential in this market and we look forward to expanding further.

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Jan-Feb, 2021

PRODUCT DEVELOPMENT

Eurolls: Rolls and Rolling Cassettes for the Wire Industry Eurolls S.p.A., founded in 1987, is recognized for the design and production of steel rolls and accessories for tungsten carbide rolls, wire cassettes and a large range of machinery for the wire industry. Its 4 plants are located in Italy with subsidiaries and branches spread across the USA, Brazil, Mexico and China.

Rolls for Construction Wire:

Eurolls has produced and sold more than 10,000 cassettes all over the world. The company has also carried out new developments in this sector which consists of an implementation of the quality of rolls surface utilizing special coatings leading to improved life span. Moreover, looking at the growth potential, Eurolls considers Indian as an interesting and very receptive market — specifically for construction wires.

The company offers the following product range for different applications:

CONSTRUCTION WIRE Rolling Cassettes Type CA and CB:

These rolls are provided with new surface coatings that increase their life and improve the quality of the final product. The sizing, forming and reducing rolls made of either tungsten carbide or steel are used to produce smooth or ribbed wire for use in the construction sector. Profiling rolls are tungsten carbide rolls that are demanded for wire ribbing or indenting, and roll holders are made of steel and hold the sizing, forming, reducing, and profiling rolls.

INDUSTRIAL WIRE Microcassettes

The CA and CB rolling cassettes (CL25CB33 and CL30CA33) offered by the company are mostly used to process low carbon wire for the construction industry.

These cassettes are normally mounted on one or more drafts machines, where the wire is reduced and/or deformed, used as a base for lattice girders, mesh, or generally reinforced concrete application. Each model can cover different ranges on entry and exit wires according to several parameters which will be evaluated from time to time.

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Jan-Feb, 2021

PRODUCT DEVELOPMENT With constant research and development — the company has developed a deep knowledge of the cold rolling process, and with the use of ‘rolling cassettes’, the cold rolling wires has replaced the traditional die drawing method in many applications.

Eurolls’ Microcassette type-C (CL20C133, CL25C133 and CL30C133) are suitable for achieving tight tolerances when processing different materials. It easily replaces traditional die boxes on multi-pass lines due to its compact dimensions. The advantages of this technology are many, starting from having a longer roll working life compared to that of traditional dies, time-saving in tooling changes, less machine downtimes, the possibility of working at higher speeds, reduction of absorbed power, lower lubricant consumption and consequently increased productivity.

These cassettes are water-cooled and have lubrication points. The company has also launched a new model — CL20C133, which comes with a reduced dimension in order to allow it to be used on compact machines.

Modular Cassettes

Modular cassettes type-D (CL20D20, CL25D20 and CL30D20) are specifically designed to process special wires such as flux-cored, titanium, stainless steel and other delicate materials. These cassettes are water-cooled and have lubrication points. Due to their compact size, they can easily replace die-box modularity: by connecting the modules in series, staggered on a 90°, multi-stage units can be formed. The advantage of this solution lies in the fact that large section reductions are distributed over several modules obtaining less variation on the final product.

Eurolls has recently introduced a new modular cassette — CL20R20, which finds application in the final drafts of a rolling line that produces welding wire having a diameter size that is less than 2mm. The reduction in its overall dimension permits this cassette unit to be installed in compact wire drawing lines.

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Jan-Feb, 2021

PRODUCT DEVELOPMENT Rolls for Microcassettes & Modular Cassettes

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Model CL-8-123HC: Used to replace the entry die in the high carbon wire process.

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Model CC-8-91: Special model designed for rope compacting.

Special Cassettes The company has developed special cassettes to meet the most varied market demands such as square profiles or others. It offers:

These rolls are mounted as 3+3 for the microcassettes and 2+2 for the modular units, and are supplied pre-assembled on their roll holders with a perfect size calibration for a dedicated profile.

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CR 170 4: Twisted square wire obtainable with Eurolls’ rotating cassette CR 170 4. This model mounts 4 rolls, where the wire enters round and the cassette gives the final twisted shape.

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CL50AS33: Steel cord compacting

ROLLS FOR DIFFERENT WIRE PROCESSING

Smart Cassette 4.0 CL25C133

Rolls for different wire processing applications:

This cassette is equipped with sensors connected either to the machine PLC or internal LAN for remote control access. These sensors can detect production parameters and therefore predict anomalies that could occur in the process. Eurolls has designed three standard packages — temperature package, productivity package and preventive maintenance package.

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Descaling rolls made of either tungsten carbide or steel used for the mechanical descaling of entry rod in reduction mills.

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Integral tungsten carbide inserts for the mechanical descaling of the entry rod into the wire production line.

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Stress relieving rolls made of tungsten carbide to improve the mechanical characteristics of the coldrolled wire.

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Tungsten carbide rolls for strips, to be used in the first roughing stands which use wire rod.

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Flattening rolls made of tungsten carbide and are used for metal strips for electrical contacts.

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Roughing rolls made of tungsten carbide.

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Motorized rolls for wire pulling.

Eurolls also produces rolls for special applications: •

Rolls for hot rolling are made of steel or with tungsten carbide insert for the hot rolling of copper or aluminum wire rod.

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Straightening rolls and cylinders are used on straightening machines to produce Z, L, T and hotrolled angles. These rolls are made of special high yielding steel, forged and treated in various phases.

High Carbon Cassettes The company has also extended the use of cold rolling cassettes into sectors such as reduction of high carbon wire, and compaction of high carbon and stainless steel strands.

Products range includes: •

EHC95: This cassette has been specifically designed to produce High Tensile Strength wires, like those used to produce P.C. strand.

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Jan-Feb, 2021